FRN Seminar Notes PDF

May 13th 2005 femfat.support@ecs.steyr.com 1 www.femfat.
com
WORKSHOP for Newcomer
WORKSHOP for Newcomer
May 13th 2005 femfat.support@ecs.steyr.com 2 www.femfat.com
FEMFAT FEMFAT - -BASIC BASIC
- -PLAST PLAST
- -BREAK BREAK
- -HEAT HEAT
- -EHD EHD
- -NVH NVH
- -FEDIS FEDIS
FEMFAT FEMFAT - -WELD WELD
FEMFAT FEMFAT - -STRAIN STRAIN
FEMFAT FEMFAT - -MAX MAX
FEMFAT FEMFAT - -SPOT SPOT
FEMFAT FEMFAT - -LAB LAB
FEMFAT - Finite Element Methode FATigue
FEMFAT FEMFAT Visualizer Visualizer
Application of specimen data to components
Load Cycles
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
F F
Load Cycles
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
Surface
Size
Heat Treatment
Stress Ratio
Type of Loading
Notches
Temperature
?
S/N Curve: Definition
Log (Load Cycles)
Log (Stress Amplitude)
UTS
Endurance
Limit
C
y
c
l
e

L
i
m
i
t
Miner Original
M
i
n
e
r

M
o
d
i
f
i
e
d
M
i
n
e
r

E
l
e
m
e
n
t
a
r
y
Inclination k = cot ()= a/b = 1/m
a
b
Stress Tensors
Material Properties
Stress Gradient
Mean Stress Influence
MultiAXial Load
Technological Influences
Size Influence
Temperature Influence
PLASTic Deformations
SPOT Joints s
Anisotropical Behaviour
of Arc WELDs
etc.
FEMFAT Local Stress Concept
S/N
1
modified
by FEMFAT
Load Cycles
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
S/N material
from specimen tests
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
S/N
1
Load Cycles
S/N material
Local Component S/N curve at any Node
S/N
1
Load Cycles
S/N material
S/N
2
Load Cycles
S/N material
MBS / MD
ABAQUS
MECHANICA
MEDINA
PATRAN
ANSYS
NASTRAN
I-DEAS
COSMOS
HYPERMESH
FEMFAT - Integration to FE-Systems
BASI C
MAX
WELD
SPOT
PLAST
BREAK
STRAI N
HEAT
FEMFAT
Interface
Files
Nodes
Elements
PODs
Groups
Interface
Files
Stresses
FEA
Solver
FEA
Preprocessor
I
n
t
e
r
f
a
c
e

F
i
l
e
s
L
o
a
d

H
i
s
t
o
r
i
e
s
L
o
a
d

S
p
e
c
t
r
a
M
B
S
M
e
a
s
u
r
e
m
e
n
t
MBS / MD
ADAMS
.
RPC III
Graphical
Presentation
FEA
Postprocessor
Material
Data Base
Haigh Diagrams
S/N Curves
Material
Generator
FEMFAT
Visualizer
Damages
Safety Factors
Fatigue Life
Interface
Files
FEMFAT Results: femfat.dma
E.g. Safety Factors Against Endurance Limit
Node_Label ................................... 1263N
Node_Color .................................. 0
Structural_Component ................... Basic Material
Internal_Specimen_Material_Number ........... 1
Safety_Factor_Endurance_Limit (Shell top, 3D) 6.8354E-01
Stress_Data_and_Component_S/N_Curve
Amplitude_Tensor : XX= 78.1 XY= -51.8 [N/mm2]
Top YY= 68.1 YZ= -13.6 [N/mm2]
ZZ= 39.1 ZX= 24.0 [N/mm2] LC
Mises: 107.5 MP1: 132.9 MP2: 34.0 MP3: 18.4 0
Mean_Stress_Tensor: XX= 0.0 XY= 0.0 [N/mm2]
Top YY= 0.0 YZ= 0.0 [N/mm2]
ZZ= 0.0 ZX= 0.0 [N/mm2]
Mises: 0.0 MP1: 0.0 MP2: 0.0 MP3: 0.0
Stress L.: 73.5 Slope:7.6071E+00 Cycle L.: 7774273
Mean_Stress_ XX= 0.0 XY= 0.0 [N/mm2]
Rearrangement_ YY= 0.0 YZ= 0.0 [N/mm2]
Tensor Top ZZ= 0.0 ZX= 0.0 [N/mm2]
Relativ_Stress_Gradient (Shell top, 3D) ... 0.3028E+00 [1/mm]
Surface_Roughness ......................... 1.0 [mum]
Technological_Size_of_Component ........... 7.5 [mm]
Tempering_Cond.(for_Temp.Steel_only) ...... 1000.0 [N/mm2]
Temperature_at_node ....................... 20.0 [C]
General input data of current computation
Specimen material data
Status of activated S/N curve influence factors at group
Structural node data
Max. damage / min. endurance safety factor
Computed S/N-curve for max. damaging
Load-spectrum portion
FEMFAT Results: femfat.pro
FEMFAT Results: femfat.msg
Error messages and warnings
that occur during the calculation
are stored in the *.msg file.
FEMFAT - Additional Analysis Outputs
Computed S/N Curve
Specimen S/N Curve
FEMFAT - Additional Analysis Outputs
Modified Haigh Diagram
Each point (
A,i
,
M,i
)
represent one
cutting plane.
Original Haigh Diagram
FEMFAT Results: Equivalent Stress History
FEMFAT Results: Damage History
Damage History
FEMFAT Online Manual
FEMFAT BASIC
FEMFAT BASIC
Reliable and effective assessment of FEM
results
Including all common FEM interfaces
Fatigue analysis for one amplitude-, mean-
and constant stress
Damage analysis for general stepped-,
rainflow- and synthetic-load spectra
Safety factor against fatigue stress
Material database for about 350 steels, cast
irons, aluminium alloys, magnesium
Consideration of many interacting fatigue
influences like material, notches, surface-
treatment, temperature, etc.
FEMFAT - BASIC Features
Oscillating
Compressive Load
Alternating
Load
Oscillating
Tension Load
L
1 < R
R = -
- < R < -1
R = -1
-1 < R < 0
R = 0
0 < R < 1
2
L U
A

=
2
L U
M

+
=
UPPER
LOWER
R
=
2 Variants to Describe a Load Cycle
Two Variants to Describe the Load
Amplitude Stress / Mean Stress
Upper Stress / Lower Stress
Import of Stresses: Two Variants
Choose Between Two
Variants
Import of Amplitude and Mean Stresses
Amplitude = 2 kN
Mean = 2 kN
FEMFAT
calculates
11 kN
Example:
Load Case 1
0 to 11 kN
Amplitude stress Factor LC 1:
Mean stress Factor LC 1:
75 , 2
2
5 , 5
=
75 , 2
2
5 , 5
=
Amplitude stress
11 / 2 =5,5
Mean Stress
11 / 2 =5,5
0 kN
5,5 kN
15 kN
5 kN
Example:
Load Case 2
5 to 15 kN
Amplitude stress Factor LC 2
Mean stress Factor LC 2
5 , 2
2
5
=
5
2
10
=
Amplitude stress
(15-5) / 2 =5
Mean Stress
(15+5) / 2 =10
10 kN
Imported Stress Amplitudes for 2 kN AND
Imported Mean Stresses for 2 kN
Import of Amplitude and Mean Stresses
2. Edit Scaling
Factors for
Amplitude and
Mean Stress
1. Create a Load
Spectra with Name
and other
Information
3. Save Spectra if
needed later
Specimen Material Data
Load Spectra
Rainflow
Stepped
Synthetic
Process of a FEMFAT Analysis
RESULTS
Damage Values,
Endurance
Safety Factors,
Analysis Report
FE- Data
Nodes & Elements
Physical
Properties
Group Data
Stress Result Data
Amplitude Stress
Mean Stress
Constant Stress
Fatigue Influences
FEMFAT BASIC
Crack Location in Test
Minimum Endurance Safety
Mass Balance Unit
Comparison of FEMFAT to Test Results
Test: 400 000 Cycles
FEMFAT: 300 000 Cycles
Clutch Shaft
Run FEMFAT with Parameter
Run FEMFAT with Parameter
-
-
ini
ini
Handling Memory with FEMFAT
After starting FEMFAT
with the paramter
femfat ini
It will come up with the
following window,
where you can among
others adjust settings
regarding memory
allocation.
Relevant for memory allocation are
Maximum Number of nodes
Maximum Numberof Elements
Highest allowable node label
Highest allowable element label
You get these characteristics from
your FE-preprocessor.
Also adjust FEMFAT-MAX: Maximum
number of channels, which is also
responsable for maximumnumber of
time steps in a TransMax calculation.
Press
Save Changes and St ar t
FEMFAT.
Instead of starting FEMFAT with
the i ni parameter you can
also edit the file f emf at . i ni
in the working directory.
Run FEMFAT As A Batch Job
Run FEMFAT As A Batch Job
Job File Batch Job
Restart FEMFAT or Create a new job with Menu File/New
Go through the items FE-Entities
Groups
Stress Data
Material Data
Load Data (Load Spectra)
Node Characteristics
Influence Factors
Analyse Parameter
Output
Protocol
like in an usual FEMFAT calculation.
Run the FEMFAT calculation.
After calculation click okay to confirm the statistics of the results.
Safe the job with menu File/Safe As. Remember the file name like for example piston_1.ffj
How To Create A Job File
# Femfat 4.4b Job File
# generated at: Wed Sep 17 15:51:56 Eastern Daylight Time 2003
#
setValue {} {} FemfatVersionNumber {Femfat 4.4b}
setValue {} {} MAXmod 0
setValue {} {} FEinputFile {C:/FEMFAT44b/Work/Example Karuna/conrod_neu.op2}
setValue {} {} StressTypeAmUl 2
setValue {0 {{setValue {} {} StressFileDatasetNumber 0}}} {0 ok} StressInputFile {C:/FEMFAT44b/Work/Example Karuna/conrod_neu.op2}
setValue {} {} StressType 2
setValue {0 {{setValue {} {} StressFileDatasetNumber 1}}} {0 ok} StressInputFile {C:/FEMFAT44b/Work/Example Karuna/conrod_neu.op2}
setValue {} {0 ok 1 ok 2 ok} MaterialReadFile {C:/FEMFAT44b/Work/Example Karuna/c45_v.ffd}
setValue {0 {{setValue {} {} NewLoadDataLabel 1 1} {setValue {} {} LoadDataName1 Example} {setValue {} {} LoadDataSection {}} {setValue {} {}
LoadDataDesignation {}} {setValue {} {} LoadDataUnit {}}}} {0 ok} LoadDataReadFile {C:/FEMFAT44b/Work/Example Karuna/Specta_1.fko}
setValue {} {} FatParamMaterial {1 - C45_V Heat treatable steel, smooth unnotched specim Probe}
setValue {} {} OutputFile {C:/FEMFAT44b/Work/Example Karuna/femfat_1.dma}
setValue {} {} ReportFile {C:/FEMFAT44b/Work/Example Karuna/femfat_1.pro}
setValue {} {0 ok} CheckInputData
setValue {} {} OutputFileComment { }
# ---START OF ANALYSIS---
setValue {} {} StartAnalysisLoop
# -----------------------
setValue {} {0 ok} OutputDialog
setInterior selectItem 1.1.9.2
Job File Batch Job
also change
Name of load spectra
Name of FEMFAT Result File
Name of FEMFAT Protocol File
Modify Your Job File piston_1.ffj
And Safe It Under A Different Name Like piston_2.ffj
Job File Batch Job
Create a Batch file called for example All_Jobs.bat
with a text editor that looks like
Your FEMFAT installation path/bin/bin/femfat.tcl -job=piston_1.ffj
....
....
On an Unix platform make sure that the file All_Jobs.bat has the mode as an
executable.
Than just run All_Jobs.bat in your working directory
THEORETICAL BACKGROUND
THEORETICAL BACKGROUND
NOTCH INFLUENCE
NOTCH INFLUENCE
According W. Schuetz, 1968, Germany
Fatigue Strength of Steels
K
= stress concentration factor
R = -1 alternating
Increasing UTS and price
Power Flow
Stress Distribution
Stress Concentration
N
a
F F
Local S/N curve in Specimen
location 1
location 1
S/N curve location 1
location 2
location 2
S/N curve location 2
Test Example Support Effect
F
1
F
1
A
a endur 1
A
F
1
=
a endur 1
F
2
F
2
a endur 2
A
F
2
=
a endur 2
K
t
Support Effect
a endur 1 < a endur 2
Relative Stress Gradient
K
f
Free Notch Assessment
=
dx
d
max
1
'
Stress Gradient
dx
d
=
No Nominal Cross Section A
nominal
definable.
Stress concentration can be characterized by stress gradient.
Why not use stress gradient for notch effect?
max
F
endurance
stress
Influence of Stress Gradient to the Fatigue Strength

Bending =2/b
=2/b
a Bending
M M
Tension / Compression
alt TC
=0
a Tens / Comp
=0
F F
( )
( )
v
v
TC alt Bending alt
enDur G
b
f '
2
1
1

+ =
Infl uence of the gradi ent on the l ocal S/N-endurance stress l i mi t
1,00
2,00
3,00
4,00
5,00
6,00
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50
r el. st r ess gr adient
'
f
G
R
,

a
f
St37
St52
42CrMo4
GS40
GGG40
GG25
AlSi10Mg
according to FEMFAT / Eichlseder
Load Cycles
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
S/N material
from specimen tests
Modification of
Fatigue Stress
Infl uence of the gradi ent on the i ncl i nati on of the l ocal S/N curve
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
1,00
1,10
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50
'
k
C
,
G
R
/
k
M
St37
St52
42CrMo4
GS40
GGG40
GG25
AlSi10Mg
Influence of Relative Stress Gradient to the Inclination
according to Hck, Thrainer, Schtz
Influence of Stress Gradient to the Inclination
Load Cycles
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
S/N material
from specimen tests
Modification of
Inclination
Infl uence of the gradi ent on the l ocal S/N-endurance cycl e l i mi t
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
1,00
1,10
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50
'
f
G
R
,

c
f
St37
St52
42CrMo4
GS40
GGG40
GG25
AlSi10Mg
Influence of Stress Gradient to the S/N Curve Cycle Limit
according to Hck, Thrainer, Schtz
Influence of Stress Gradient to the Cycle Limit
Load Cycles
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
S/N material
from specimen tests
Modification of Cycle Limit
MEAN STRESS INFLUENCE
MEAN STRESS INFLUENCE
CRITICAL PLANE APPROACH
CRITICAL PLANE APPROACH
FEMFAT Mean-Stress Influence HAIGH Diagramm
Admissible Stress Amplitude according to
Tensile Stress or
Pressure Stress
Polygon line Haigh-Diagrams
Dependent on material class code
Material dependent equivalent stress
R

=

0
R

=

-
8
1
2, 3
4
5
6, 7
8
9
R
p 0,2
R
m

m
a
Steel
Mean Stress
Amplitude
Stress
Grey Cast Iron
R

=

0
R

=

-
8
1
2
3
4
5
6
30
7
8
9
R
m
d, B
a
Mean Stress
Amplitude
Stress
Construction of the HAIGH Diagram
Stress
Amplitude
Mean Stress
M
e
a
n
=
0
Y
i
e
l
d
U
T
S
Y
i
e
l
d
U
C
S
A
l
t
e
r
n
a
t
i
n
g

L
o
a
d
P
u
l
s
a
t
i
n
g

L
o
a
d
9
6,7
2,3
1
4
5
Compression
Area
Tensile
Area
8
Mean Stress Influence: a Simple Example
Critical
Cutting
Plane
Mean stress
Amplitude
v Mises M1
v Mises A1
v Mises A1
=
v Mises A2
But:
Damage 1 Damage 2
v Mises M1
=
v Mises M2
TEST 1
Mean stress
Amplitude
v Mises M2
TEST 2
v Mises A2
a n
m n
Mean stress effect in FEMFAT BASIC

Current Cutting Plane
depending on and
A
+
M
-
M
2
2
,
2
a
alt
TC alt
n a e a

+ =
( )
2
2
2
m
Yield
Yield
n m n m e m
sign

+ =
m e ( )
a e ( )
A
Mean stress effect in FEMFAT BASIC
+
M
-
M
a e crit
a endu
a n
m n
Criteria (m=const)
for critical
loading point:
Min
a endu
a e crit
HAIGH diagram and loading points
are calculated for all cutting planes
FEMFAT Mean Stress Influence: Load Criteria
Criteria
for critical
loading point:
min
1
+
2

M
= const

Lower
= const

Upper
= const
R = const
HAIGH diagram

A
+
M
-
M
M

=

c
o
n
s
t
R
=

c
o
n
s
t

&
C
O
N
S
T

=

0
L
o
w
=

c
o
n
s
t
R
=

c
o
n
s
t

a
n
d

C
O
N
S
T

CONST
U
p

=

c
o
n
s
t
critical loading point
Influence of Stress Gradient Fatigue Stress
Load Cycles
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
S/N material
from specimen tests
Modification of Fatigue Stress
Negative influence of mean stress in this example.
Influence can be positive for compression as well.
Modification of Endurance Limit Due to Mean Stress
Load Cycles
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
Modification of Fatigue Stress due to
mean stress by the factor
ALT,Sm
ALT, TC
f
m
=
Mean Stress
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
U
T
S
U
C
S
ALT,TC
MEAN, TC
ALT,Sm
f
m
Which Equivalent Stress?
Automatic (default)
Von Mises
Max/Min Principle
Normal Stress in
Critical Plane (for Grey
Cast Iron)
Equivalent Stress in
Critical Plane (for Steel
and Aluminum)
Automatic Stress Selection means:
Normal Stress in Critical Plane for Grey Cast Iron
Equivalent Stress in Critical Plane for Steel and Aluminum
Creating Component Haigh Diagram
Mean Stress
S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
U
T
S
U
C
S
ALT,TC
Material Haigh Diagram
Starting Point: Material Haigh Diagram
U
C
S
U
T
S
1
st
Step: Modified Haigh Diagram
UTS and UCS are modified due to
support effect
Component Haigh Diagram
f
total

ALT,TC
2
nd
Step: Component Haigh Diagram
Vertical Displacement of Haigh Diagram
due to all influences to the endurance
limit.
Palmgren Miner
Palmgren Miner
Damage d
1
=
n
1
N
1
MINER Rule in FEMFAT
A
M
P
L
I
T
U
D
E
- +
MEAN
Crack is initiated at
d
total
= 1
Analyzed S/N Curve at a
FE-Node by FEMFAT...
A
1
n
1
N
1
S
T
R
E
S
S

A
M
P
L
I
T
U
D
E
(
l
o
g
)
N (log)
... for a certain
survival probability in%
Load spectrum entry
A
1
, M
1
, n
1
Total Damage:
D = d
i
= d
1
+ d
2
+ d
3
+ ... + d
n
- +
MEAN
A
M
P
L
I
T
U
D
E
A
3
M
3
n
3
A
2
M
2
n
2
A
1
M
1
n
1
d
i
=
n
i
N
i
A
1
n
1
S
T
R
E
S
S

A
M
P
L
I
T
U
D
E
(
l
o
g
)
N (log)
N
1
N
2
N
3
A
2
A
3
n
2
n
3
S/N
1
S/N
2
S/N
3
Analysed S/N Curves at a
FE-Node by FEMFAT
FEMFAT Results: Damage by Palmgren Miner
Safety Factor Analyze
Safety Factor Analyze
A
S
T
R
E
S
S

A
M
P
L
I
T
U
D
E
(
l
o
g
)
N (log)
Endurance Safety Factor
Analysed S/N Curve at a
FE-Node by FEMFAT
Endurance
M
SF
A
=
Endurance
A
SF
B
=
Endurance
+
M
A
+
M
M
= const
TEMPERATUR INFLUENCE
TEMPERATUR INFLUENCE
0
0.2
0.4
0.6
0.8
1
1.2
0 200 400 600
St37
St52
42CrMo4
GS40
GGG40
GG25
AlSi10Mg
According FKM-Guideline
Influence of Temperature
) 100 ( 10 1
3
, ,
C T a f
af T af TE
=

) 10 ( 0 . 1 1
3
,
T f
af TE
=

2 3
, ,
) 10 ( 1 T a f
D T af TE
=

) 50 ( 10 1
3
, ,
C T a f
D T af TE
=

Rolled Steel
Fine grained steel
Grey Cast Iron, Nodular Cast Iron
Aluminum
Reading in Temperature Fields
1. Go to Nodal
Characteristics
2. Choose file
format in which you
want to import the
temperature field.
3. Define the path to
the temperature file
fromFEA.
Available interfaces
SDRC Universal File
NASTRAN Punch
SDRC MS Universal File
Ansys (ASCII)
Patran.rpt
Medina
ProMechanica (ASCII)
NASTRAN OP2 (binary)
Abaqus FIL (binary)
Reading in Temperature Fields
4. Go to Influence
Factors
5. Activate the
Isothermal
Temperature
Influence
FEMFAT Isothermal Temperature Influence
Log (Load Cycles)
Specimen S/N Curve
at ambient Temperature
Component S/N Curve
modified to current
temperature
Among all other
influences also the
temperature modifies
the endurance limit at
any node of the
structure.
OTHER INFLUENCES
OTHER INFLUENCES
0,50
0,60
0,70
0,80
0,90
1,00
1,10
0 25 50 75 100 125 150 175 200 225
R
Z, B
f
S
R
,

a
f
St37
St52
42CrMo4
GS40
GGG40
GG25
AlSi10Mg
Influence of Surface Roughness in FEMFAT
According IABG: Valid for UTS < 1200 MPa
Surface Roughness in m
F
a
t
i
g
u
e

I
n
f
l
u
e
n
c
e

F
a
c
t
o
r
) lg 45 . 0 (lg ) (lg 22 . 0 1
) lg 45 . 0 (lg ) (lg 22 . 0 1
,
53 . 0
,
64 . 0
,
53 . 0
,
64 . 0
,
M Z M Z
C Z C Z
R UTS R
R UTS R
af SR
f
+
+
=
0,80
1,00
1,20
1,40
1,60
1,80
2,00
0,00 10,00 20,00 30,00 40,00 50,00
sample t hickness d
P
f
R
O
,

a
f
= 0
= 0,5
= 1
= 2
= 5
= 10
Sample Thickness
F
a
t
i
g
u
e

I
n
f
l
u
e
n
c
e

F
a
c
t
o
r
Influence of Surface Treatment

- 1
220
GK_Al Si 10Mg( WA) Al umi numDi e Cast at 20
Cent i gar de
Const ant s f or condi der i ng DAS
7. 100 0. 380
39. 4 0. 317
10
10. 1. 000
20. 1. 000
30. 1. 000
40. 0. 967
50. 0. 934
60. 0. 902
70. 0. 863
80. 0. 825
90. 0. 787
100. 0. 749
- 1
New Dataset in the Material File: E.g. : GK_ALSI10Mg(WA).ffd
Can be used for porosity influence as well by editing the material file
F
a
t
i
g
u
e

L
i
m
i
t

F
a
c
t
o
r
Influence of Dendrite Arm Spacing in FEMFAT
Dendrite Arm Spacing
Activation of Influences in FEMFAT
0 ln ln ln
0
1
0
1
0
1
= + +
h
h
b
b
l
l
Effective Plastic Strain
Volume Constancy
=
2
0
1
2
0
1
2
0
1
ln ln ln
3
2
h
h
b
b
l
l
V
Influence from Forming Simulation since V4.4

100
1000
1 10 100 1000 10000 100000 1000000 1E+07
Number of Cycles
S
t
r
e
s
s

[
N
/
m
m
^
2
]
Phi V1 Phi V2 Phi V3
0
50
100
150
200
250
300
350
400
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
Strai n [%]
S
t
r
e
s
s

[
N
/
m
m
^
2
]
Phi V1 Phi V2 Phi V3
Material St14
S-N curve
Cyclic - curve
Phi V1 = 0
Phi V2 = 0,138
Phi V3 = 0,248
Fatigue Limits
148MPa
174 MPa
194 MPa
Influence from Forming Simulation, Interface to LS-Dyna
STATISTIC INFLUENCE
STATISTIC INFLUENCE
IN FEMFAT
IN FEMFAT
FEMFAT Statistic Influence
Activate the Statistical
Influence
Determine the Survival
Probability according to
your demands.
The Material file contains
the survival propability for
which the specimen S/N
curve was generated.
The specimen S/N curve is
modified by all influences
like notches, surface
roughness, temperature,
mean stress AND the
survival probability
Log (Load Cycles)
Specimen S/N Curve
for e.g. 50%
Component S/N Curve
modified to e.g.10%
Component S/N Curve
modified to e.g.90%
Gaussian Bell Shaped Curve
S/N curve is modified according to demanded survival probability.
Enter the Range of
Dispersion.
1.26 is recommended by
literature.
The range of dispersion is defined as the ratio of component fatigue strength at
10 percent survival probability to component fatigue strength at 90 percent
survival probability.
The default value is 1.26 (literature recommendation).
Turning on and Off the Statistical Influence
Deactivating the Statistical Influence leads to the analysis of the component
S/N curve at the nodes proceeding without consideration of the defined survival
probability and the range of dispersion specified at the nodes. The survival
probabilities of the underlying specimen S/N curve are used.
Method of analysis for statistical influence
A Gaussian normal distribution is currently assumed for analysis of the statistical
influence parameters.
The fatigue strength is converted, whereby the following quantities are
considered:
Survival probability of the type-dependent S/N data (material data) Range of
dispersion (node characteristics)
Required survival probability of result, depending on input (analysis parameter)
COMBINATION OF INFLUENCES
COMBINATION OF INFLUENCES
Combination of Influence Factors
f
ST,af
Statistic Influence Factor
f
GR,af
Gradient Influence Factor
f
m,af
Mean Stress Influence Factor
f
TS,af
Technological Size Influence Factor
f
1,af
Roughness / Forge Influence Factor
f
2,af
Technological Surface Treatment Influence Factor
f
TE,af
Thermal Influence Factor
f
GE,af
General Influence Factor
af GS af TE af af TS
af m
af af GR
af ST
af tot
f f f f
f
f f
f
f
, , , 2 ,
,
2
, 1
2
,
,
,
0 , 1
1

+
=
Influences to the endurance limit
Combination according TGL 19340 / FKM 94
IFK2 Parameter of the material
Influences to the Inclination
k
M
Inclination of the component S/N curve at alternating load (R=-1)
f
,m,sf
Influence factor of the mean stress on the inclination of the S/N curve
k
C
Inclination of the local component S/N curve
f
GR, sf
Influence factor of the stress gradient on the inclination of the S/N curve
sf m
IFK
af
IFK
sf GR
M
C
f
IFK
f
f
IFK k
k
,
3
, 1
3
,
1
2
1
1
2
+
+
=
N Parameter of the material
Influences to the Cycle Limit
k
M
Inclination of the component S/N curve at alternating load (R=-1)
N
,cf,C
Cycle Limit of local component S/N curve
k
C
Inclination of the local component S/N curve
N
cf, M
Cycle Limit of component S/N curve at alternating load (R=-1)
=
M
C
k
k
M cf C cf
N N
6 . 3
8 . 6
6 . 3
8 . 6
, ,
10
10
FEMFAT PLAST
FEMFAT PLAST
FEMFAT PLAST / Neuber Hyperbola
S
t
r
e
s
s
2

(
M
a
x
-
M
e
a
n
)
Strain
Mean Modified
Max Modified
Min Modified
2

(
M
a
x
-
M
e
a
n
)
Neuber-Hyperbola
Max
Min
Mean
2

(
M
a
x
-
M
e
a
n
)
FEMFAT PLAST
Consideration of local plasticizing after a calculating stresses
with linear stress-strain curve
Based on Cyclic Stress Strain Curve
Mean Stress Rearrangement according to Neuber
Estimation of Sequence Influence
Compatible to FEMFAT MAX
meanFE
mean modifi ed
max
max, modified
2
m
a
x
-
m
e
a
n
)
(
S
t
r
e
s
s

Strain
H
o
o
k
:

e
las
top
lastic Material: = f()

max, modified max, modified max
= /E
FEMFAT BREAK
FEMFAT BREAK
FEMFAT BREAK: Safety Factor of Static Overload
Available are
Ultimate Stress Limit
Yield Stress
Elongation at Rupture A5
Linear stress results
Static Safety factor considers
Relative stress gradient
Ductility
Elastoplastic Material Properties
Strain
S
t
r
e
s
s
Linear stress result
Y
o
u
n
g
s

M
o
d
u
l
u
s
FEMFAT BREAK: Safety Factor of Static Overload
SF
BREAK
=
ADMISSIBLE
FE max
2
b
Local relative stress gradient 0
Neuber Hyperbola
. = const
Strain
nonlinear
material
behaviour
Ult. Tension
Ult. Bending
A
d
m
i
s
s
i
b
l
e

S
t
r
e
s
s

Neuber Stress Limit
Known points fromspecimen Tests
Housing
Nonlinear contact,
radial, axial
Shaft
Nonlinear contact,
conical
Outer bearing ring
Detail:
Taper Roller
Static Safety Factors
FEMFAT BREAK Gearbox analysis
Equivalent Stress
FEMFAT MAX
FEMFAT MAX
Reliable and effective assessment of
complex loads
Interfaces for history data to Multi
Body Systems and Measurement Data
Software (ADAMS, RPC, DIAdem, ...)
Channel based or transient load
definition
Filters for high computation
performance
Endurance safety factors for multiaxial
load
Unlimited number of loads and
histories
Compatible to FEMFAT-WELD and
FEMFAT-SPOT
FEMFAT - MAX Features
Results
Damage Values
Endurance Safety Factors
Life
FEMFAT CHANNEL MAX
FEMFAT MAX
F
V
=
Channel 1
F
S
=
Channel 2
F
L
=
Channel 3
Stress Gradient in Channel MAX
C
h
a
n
n
e
l
1
C
h
a
n
n
e
l
2
C
h
a
n
n
e
l
N
1. Imported
stress
dirstibution
N

N
2. Gradient
calculated
for each
channel

1

2
A
max1
3. Finding
maximum
in each
force history
A
maxN
A
max2
maxN
=
A
maxN
MisesN
4. Calculation
of equivalent
stress
amplitude
max1
=
A
max1
Mises1
max2
=
A
max2
Mises2
5. Calculation
of weighted
Stressgradient
N...Number
of Channels
=
=

=
N
i
i
N
i
i i
1
max
1
max

FEMFAT TRANSMAX
0
10
20
30
40
50
60
70
80
90
0 180 360 540 720
Combustion
Pressure +
Mass Forces
Transient Load Condition
in Time
Results
Damage Values
Endurance Safety Factors
Life
One Stress Result for
Each Time Step
FEMFAT MAX
Stress Gradient in Trans Max: Time Mean Value
T
i
m
e

S
t
e
p

1
T
i
m
e

S
t
e
p

2
T
i
m
e

S
t
e
p

N
1. Imported
Stress
N
2. Calculation of
Stress Gradient
N
3. Calculation of Average of
Gradient over Time
=
=
N
i
i
N
1
1

N...Number of
Time Steps
Stress Gradient in Trans Max: Max Stress Difference
T
i
m
e

S
t
e
p

1
T
i
m
e

S
t
e
p

2
T
i
m
e

S
t
e
p

N
Imported Stress
N
Gradient is calculated for
the Biggest Mises
Stress Amplitude
Calculation of nine Mises
Stress Amplitudes
Nine Difference-Tensors of
=
Max
-
Min
Nine possible
combinations of
3
Max
and 3
Min
Calculation of
Pricipal Stress
Histories
p
r
i
n
c
_
x
x
i=1 to N
p
r
i
n
c
_
y
y
p
r
i
n
c
_
z
z
i=1 to N
i=1 to N
Finding 3
Max
and 3
Min
one for each Pricipal
Stress History
Max xx
Min xx
Max yy
Min yy
Min zz
Max zz
Benefits of new FEMFAT-MAX transient analysis
Flexible
No superposition
No linearity between time steps
required
Fully automated input/output
file handling
High disk space efficiency
Low disk access rate entails
low network load
The directions of the principal stresses
are changing permanently.
Therefore classic criteria like
Maximum Principal Stress
Von Mises Stress
Octahedral Shear Stress
etc.
are not applicable for
multiaxial fatigue analysis.
Multiaxial Fatigue Analysis
Critical Plane Criterion
E
x
t
e
r
n
a
l

F
o
r
c
e

F
1
(
t
)
External Force F
2
(t)
E
x
t
e
r
n
a
l

T
o
r
q
u
e

M
1
(
t
)
dA
Internal Reaction
Force dF(t)
N
o
r
m
a
l

V
e
c
t
o
r

n
Internal Reaction
Force dF
Shear
(t)
Internal Reaction
Force dF
normal
(t)
FEMFAT MAX Critical Plane Criterion
Transformation of all load tensors
into several planes
Filtering of interesting planes
Generation of the load histories
of the stress components
Rainflow counting in all planes
Damage analysis
(Influence Parameter Method)
The cutting plane with maximum damage is
assumed to be the critical plane for fatigue failure
) (
) (
) (
zz z zy y zx x z
yz z yy y yx x y
xz z xy y xx x x
n n n e
n n n e
n n n e

+ + +
+ + +
+ + =
a n
m n

Equivalent Stress in the Critical Plane
2
2
,
2
,
;

=
alt
TC alt
n
alt
TC alt
n e Max sign
x
y
z
a
, n
Nokleby criterion
a
a
n

=
=
( ) ( ) ( )

+ +
+ +
+ +
alt
TC alt
y x n
alt
TC alt
y x n
alt
TC alt
y x n

,
2
,
2 2 2
,
( )
2
2
,
2
+ =
alt
TC al
t
n n e
sign
alt
=
Normal Stress
n e
,
=
TC alt
e

Method4.2 accordingDr. Gaier
Shear Stresses
Signed Equivalent
Stress 1
Signed
Equivalent
Stress 2
Critical Plane / Critical Component
Methode FEMFAT4.2: Stress Vector Projection
S
n,d
(t) = S
n
(t) d
Plane
n
S
n
(t)
n ... Normal Vector of Plane
S
n
(t) ... Stress Vector
d ... Unit Vector for Stress Projection
S
n,d
(t) ... Stress Component inDirection d
d
.
S
n,d
(t) Stress component S
n,d
(t)
in direction d is used for rainflow-
counting and damage analysis:
Stress component with maximum
damage is assumed to be critical
for fatigue failure
Critical Plane Critical Component
Criterion
.
.
S
n
(t)
N
n
(t)
T
n
(t)
T
n,d
(t)
N
n,d
(t)

Cutting Plane
n
S
n,d
N
n,d
T
n,d
.
n ... Cutting Planes Normal Vector
S
n,d
... Stress Component in Direction d
N
n,d
... Normal Stress
T
n,d
... Shear Stress
= 0 ... pure Tensile Load
= 90 ... pure Shear Load
= 180 ... pure Compressive
Load
.
Methode FEMFAT4.2: Stress Vector Projection
1
R1
0
100
200
300
400
500
600
700
800
900
1000
E
n
d
u
r
a
n
c
e

L
i
m
i
t

[
M
p
a
]
Mean St r ess [ Mpa]
P
o
l
a
r

A
n
g
l
e

[
d
e
g
]
-850 850 0
90
0
Methode FEMFAT4.2: Haigh Diagram Tempering Steel
1
R1
0
50
100
150
200
250
300
350
400
450
500
E
n
d
u
r
a
n
c
e

L
i
m
i
t

[
M
p
a
]
Mean St r ess [ Mpa]
P
o
l
a
r

A
n
g
l
e

[
d
e
g
]
0
90
-960 300 0
Methode FEMFAT4.2: Haigh Diagram Grey Cast Iron
Advantages:
- Independent from coordinate system
- Normal and shear stress and all their combinations are taken into account
- Applicable for non-proportional stochastic loading
- No discontinuities in stress histories, Rainflow-counting is problem-free
- Applicable for both brittle and ductile materials by specifying cyclic data in
dependence on the polar angle (Haigh-diagram, S/N-curve, etc.)
- Interpolation between tensile/compressive and torsion load can be adapted
to test results
- Generally applicable for bi- and triaxial stress states
- Physical interpretation possible as critical component of stress vector
Disadvantage:
- High computation effort
Method FEMFAT4.2
Use Group with Critical Areas
0 20 40 60 80 100 120 140 160 180
maximum equivalent stress for channel 1
upper equivalent stress
filter limits
selected planes
Example with 3 Channels
Critical Plane Filter Method 1
Loop over surface nodes
Does the node lie on an
inwarding notch?
NO YES
plane-normal-
vectors:
Plain stress
n
S u r f a c e
plane-normal-
vectors:
3D - stress
n
S u r f a c e
n
S u r f a c e
User Definition
FEMFAT MAX Cutting Plane Filter
-10
-5
0
5
10
15
0 10 20 30
F X
F Y
F Z
Const
C
a
l
i
b
r
a
t
i
o
n

F
a
c
t
o
r
s
Time (short part)
BMW Benchmark: Aluminium Axle Component
TEST: 2420 Periods
FEMFAT: 3020 Periods
TEST: 2160 Periods
FEMFAT: 3690 Periods
BMW Munich decided
to buy FEMFAT
after the benchmark
Von Mises Stress and
Histories
Damage Distribution
FEMFAT Result
Damage Distribution
FE
Modal Stresses
1

2
n
Component Modes
1

2
n
MBS
and
(E)HD
(Co - Simulation)
q
n(t)
q
2(t)
q
1(t)
Modal
Coordinates
Channel 1
Channel 2
FEMFAT
1
q
1(t)
2
q
2(t)
q
n(t)

n
Channel n
Additional
Load Cases
(Screwing,...)
Fatigue
Lifetime prediction of
dynamic loaded parts
considering dynamic effects
due to natural vibrations
Hybrid Models: FE+MKS+FEMFAT
Fatigue Results - V6 engine
rpm sensitive fatigue analysis
endurance safety distribution
identification of resonances
Campbell diagram:
boundary conditions:
(constant moment,
constant rpm)
modally based fatigue
lifetime prediction with
FEMFAT-MAX
considers dynamic
effects like resonance
excitations!
reasonable simulation time
FEMFAT: Which Module is to Use?
Module When to use Examples What to Import
BASIC Direction of principle stresses
are constant
2 Load Conditions
Con rod with the two
dominating load cases ignition
and intertial force
Engine bulkhead and bearing
cap (assambly and ignition)
Shafts with torgue history (only
one channel)
Two stress results, which
can be:
Upper and lower stress
or
Amplitude and mean
stress
Load spectra if neccessary
CHANNEL
MAX
Direction of Principle Stresses
are permanently altering
Direction and loaction of forces
and boundary conditions are
constant
Existing Load Histories
More then one channel, which
are generally not in phase
Chassis parts like:
Knuckles, subframes,
H-Arms,...
Body in White
Crankshaft with modal
approach
One stress result for each
channel (e.g. for unit load)
One load history for each
channel
TRANS MAX Load application point and
boundary conditions are
altering with time
Sequence of stress results
Engine bulkhead and bearing
cap or crankshaft with stress
result each n crankangle
Sequence of stress results
THE MATERIAL GENERATOR
THE MATERIAL GENERATOR
Required Material Data for FEMFAT
Import of Material Properties from Database
Reading Various Materials from the Database
E.g. Aluminum for the block, Steel for Valve Seats,...
FEMFAT - Material Generator
1. Select Material Group
2. Specify all information you know (and press ENTER)
3. FEMFAT computes
all other material data
for you
Using
Using
FEMFAT WELD
FEMFAT WELD
FEMFAT - WELD Features
Practicable meshing according
Automatically recognition and
assessment of the weld seams
Open database for
Notch factors
S/N curves
Haigh diagrams
Thickness influence
Graphical Results
Damage
Life
Safety Factor
Compatible to FEMFAT - MAX
Setup of FE Modell
For Example With Shell Elements
Corse Mesh
Analysis Process Step 1
Definition of Weld Seams
According to Modelling Guidelines
Weld Nodes are recognised by Node ID
Weld Type is Recognised by Element ID
No Modification of Material Properties
MAT 203
MAT 205
T
O
P
T
O
P
TOP
M
A
T

2
0
3
M
A
T

2
0
1
MAT 205
FEMFAT
Model Guidline for
T-joint
Weldtype: T-JOINT
Seamform: One sided fillet weld
2D Modelling:
Element type : THIN SHELL (quadrilateral, triangle)
Element material number : MAT201 - MAT206
Weld seam node colour : C100 ... normal weld seam node
C101 ... weld seam end, not welded around
C102 ... weld seam end, welded around
Modeling Guideline for T-Joints
a
MAT 204
MAT 206
MAT 202
C 100
t
2
t
1
t
2
a
MAT 203
MAT 205
MAT 201
C 100
t
1
100
2*t
min
2*t
min
2*t
min
2*t
min
101
100
100
Modeling Guideline for Weld Seam Ends / Starts
1
3
2
1. Certain Node ID for Start or End of Weld Seam
2. Material labels are applied around the last node
3. Element size is recommended to be 2 times of the sheet
thickness.
Calculation of Stresses
Import of Stress Results into FEMFAT
Interfaces for Numerous Common File Formats
Stress at arc weld = 106 MPa
Maximum Stress = 206 MPa
Base Material
Activating the Weld Influence
Activate FEMFAT
Weld as Influence
Factor
Interfaces to Numerious Common Postprocessors
Post Processing of Results
Damge
Safety Factors
Life
Safety factor at arc weld = 0.7
Safety factor = 1.2
(at maximum stress location, base material)
FEMFAT WELD
MAT 207 MAT 209
C 100
TOP TOP
T
O
P
M
A
T

2
1
1
Modelling Guideline
Damage,
Safety Factors
Life
Analysis Report
Analysis Process of FEMFAT WELD
WELD Database
FE-Model
Stress Results
Load Hystories
Analysis
Analysis
Process
Process
of
of
FEMFAT WELD
FEMFAT WELD
FEMFAT Weld and Local Stresses
Structural Stresses out of FE Results
All details are stored in open FEMFAT WELD database
Weld S/N Curve
Haigh Diagram form Mean Stress Influence
Influence of Shell Thickness
Notch factors
Notch Stresses are Structural Stresses multiplied by Notch factor
Structural Stresses Notch Stresses
WELD Database
Notch Factors
=
=

Projection of Stresses Into Local Coordinates
Weld Node e. g. C101
Shell Orientation
Parallel
W
e
l
d
i
n
g

S
e
a
m
Perpendicular
Anisotropic Strength Characteristics for Welding Seams
Stresses Perpendicular and Parallel to Seam are Critical
Transformation to local Coordinate System
Equivalent Strain Energy Hypothesis using HAIBACH (DIN 15018)
Equivalent Stress and Equivalent Safety Factor
=
2
2 2
1 1 1 1 1 1
shear lar perpendicu parallel lar perpendicu parallel ENDU
SF SF SF SF SF SF
=
2
,
,
,
,
,
,
2
,
,
2
,
,
,
,
parallel A
parallel a
lar perpendicu A
lar perpendicu a
parallel A
parallel a
lar perpendicu A
lar perpendicu a
parallel A
parallel a
Equivalent A
Equivalent a
=
shear parallel lar perpendicu ENDU
SF SF SF SF
1
,
1
,
1
max
1
=
shaer A
shear a
parallel A
parallel a
lar perpendicu A
lar perpendicu a
Equivalent A
Equivalent a
,
,
,
,
,
,
,
,
, , max
##This formula is still used for middle of welding seam !

Weld Start and End Nodes
The distances of the assessment points D
1
and D
2
are calculated
as follows:
( ) ( )
( ) ( )
2 1 min 2
2 2 min 1
5 . 0 1 5 . 0
5 . 0 1 5 . 0
t t t t f D
t t t t f D
neighbor ele
neighbor ele
+ = + =
+ = + =
Improved Automatic Stress Correction
Automatic Stress Correction: Example - Mesh Density
Model 5
Model 2 Model 3
Model 4
Model 1 (Ref er enc e)
Automatic Stress Correction: Example - FEMFAT Results
MODEL 4
0,00
0,50
1,00
1,50
2,00
2,50
3,00
3,50
4,00
4,50
5,00
0
,
0
0
5
,
7
5
1
2
,
1
0
1
8
,
7
5
2
5
,
0
0
3
1
,
2
5
3
7
,
5
0
4
3
,
7
5
5
0
,
0
0
5
6
,
2
5
6
1
,
9
3
6
7
,
6
0
7
3
,
8
5
8
0
,
0
4
8
6
,
2
3
9
2
,
4
2
9
8
,
3
8
1
0
4
,
4
0
1
1
0
,
6
0
1
1
6
,
7
0
1
2
2
,
7
0
1
2
8
,
7
0
1
3
4
,
6
0
1
4
0
,
7
0
1
4
7
,
0
0
1
5
3
,
0
0
1
5
8
,
3
0
1
6
4
,
6
0
1
7
0
,
8
0
1
7
7
,
1
0
1
8
3
,
3
0
1
8
9
,
6
0
1
9
5
,
8
0
2
0
2
,
3
0
2
0
8
,
9
0
2
1
4
,
7
0
Distance along the weld seam [mm]
S
a
f
e
t
y

F
a
c
t
o
r

o
f

E
n
d
u
r
a
n
c
e
MODEL 4 New Method
Reference (Model 1)
WithoutCorrection
Model 5 (Coarse)
0
1
2
3
4
5
6
0
,
0
0
5
,
7
5
1
2
,
1
0
1
8
,
7
5
2
5
,
0
0
3
1
,
2
5
3
7
,
5
0
4
3
,
7
5
5
0
,
0
0
5
6
,
2
5
6
1
,
9
3
6
7
,
6
0
7
3
,
8
5
8
0
,
0
4
8
6
,
2
3
9
2
,
4
2
9
8
,
3
8
1
0
4
,
4
0
1
1
0
,
6
0
1
1
6
,
7
0
1
2
2
,
7
0
1
2
8
,
7
0
1
3
4
,
6
0
1
4
0
,
7
0
1
4
7
,
0
0
1
5
3
,
0
0
1
5
8
,
3
0
1
6
4
,
6
0
1
7
0
,
8
0
1
7
7
,
1
0
1
8
3
,
3
0
1
8
9
,
6
0
1
9
5
,
8
0
2
0
2
,
3
0
2
0
8
,
9
0
2
1
4
,
7
0
Distance along the weld seam [mm]
S
a
f
e
t
y

F
a
c
t
o
r

o
f

E
n
d
u
r
a
n
c
e
MODEL 5 Coarse Mesh New Method
Reference (Model 1)
Without Correction
The FEMFAT Weld
The FEMFAT Weld
Database
Database
Calculation of Notch Factors
Storing Notch Factors
in Database
Kt
S/N
Haigh Diagram
Kt
S/N
Haigh Diagram
Fine FE - Model
Radaj Method
Metallographic
section of Specimen
Load Case1
Tensile/Compression
Load Case 2
Bending
Assessment Points:
Transition Area Top and Bottom
Root Top and Bottom
Notch Factor Depending on Internal Load
Assessment
Element
M
Neighbor
Element
Load Case 3
Power flow over
neighbor element
M
F
Assessment
Element
Assessment
Element
Testing of a Certain
Weld J oint
Weld Shape
Material
FEMFAT - WELD Method
1000
10000
100000
1.000E+04 1.000E+05 1.000E+06 1.000E+07 1.000E+08
Testing Result
S/N Curve
Mean/Spread
Concept
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
400
420
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
Weld Seam Endurance
Stress Limit
Y
Stored in Database
FEMFAT - WELD Database
$=======================================================================================
$ T- Wel d, Doubl e Fi l l et - Wel d Si t uat i on: 05- 01- 96
$ - - - - - - - - - - - - - - - - - - - - - - - - - -
$
$ Dat a f or a node i n t he mi ddl e of t he wel d seam
$
$ MNT MNB UTL1 UTL2 UTL3 UBL1 UBL2 UBL3 WTL1 WTL2 WTL3 WBL1 WBL2 WBL3 SPTO SPBO
$ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
207 212 1. 85 1. 85 1. 98 1. 61 1. 61 1. 61
208 212 1. 85 1. 85 1. 98 1. 61 1. 61 1. 61
209 211 1. 85 1. 85 1. 98 1. 61 1. 61 1. 61
210 211 1. 85 1. 85 1. 98 1. 61 1. 61 1. 61
211 2. 65 1. 76 2. 65 1. 76 2. 16 0. 42 2. 16 0. 42
212 2. 65 1. 76 2. 65 1. 76 2. 16 0. 42 2. 16 0. 42
$
$ BEPKT 1 BEPKT 2 BEPKT 3 BEPKT 4
$ I ncl i nat i on I ncl i nat i on I ncl i nat i on I ncl i nat i on
$ Cycl e Endur . Cycl e Endur . Cycl e Endur . Cycl e Endur .
$ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
N207 5. 00 5. 00 4. 00 4. 00
E207 1800000 1800000 1000000 1000000
N208 5. 00 5. 00 4. 00 4. 00
E208 1800000 1800000 1000000 1000000
N209 5. 00 5. 00 4. 00 4. 00
E209 1800000 1800000 1000000 1000000
N210 5. 00 5. 00 4. 00 4. 00
Including
Notch Factors
S/N Curves
Haigh Diagram
Weld Endurance Limit
Thickness Influence Factors
Medaten: Einstufenversuch (31 Kanle)
-15000
-10000
-5000
0
5000
10000
15000
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Zeit [s]
K
r
a
f
t
[
N
]
, M
o
m
e
n
t
[
N
m
m
]
Kanal 1
Kanal 2
Kanal 3
Kanal 4
Kanal 5
Kanal 6
Kanal 7
Kanal 8
Kanal 9
Kanal 10
Kanal 11
Kanal 12
Kanal 13
Kanal 14
Kanal 15
Kanal 16
Kanal 17
Kanal 18
Kanal 19
Kanal 20
Kanal 21
Kanal 22
Kanal 23
Kanal 24
Kanal 25
Kanal 26
Kanal 27
Kanal 28
Kanal 29
Kanal 30
Kanal 31
Comparison Simulation - Test bench
Multiaxial loads
Example:
Passenger Car Subframe
Stress
Distribution
Damage
Distribution
Example
Truck Frame
Comparison Simulation - Test bench
Passenger Car Subframe
Comparison FLP - Test bench
Crack location
FEMFAT SPOT
FEMFAT SPOT
FEMFAT Fatigue Analysis of Vehicle Body
Original BIW Model Automatic Local Remeshing
of Spot-Joints
FEMFAT Results
Damage Values
Input of Load histories
FEMFAT SPOT
Automatically detailed joint meshing
Compatible to common FE-systems
Improved stiffness simulation
Simulation based on test results
Applicable for new joining
technologies (Spot-welding; Self-
piercing riveting)
Automatically recognition,
identification and assessment of the
jointed areas
Open database for spot diameter,
S/N curves, Haigh Diagram
Graphical results
Compatible to FEMFAT MAX
Influence of Mesh Quality on Shell Stress Results
Global x Coordinate
M
a
x
.
P
r
i
m
.
S
t
r
e
s
s
[
N
/
m
m
]
190
150
100
50
0 40 80 120
30 mm
5 mm
10 mm
20 mm
Singular Stress Behavior
Influence of Mesh Quality on Beam Forces
0
20
40
60
80
100
120
Config 1 Config 2
Fx
Fy
Fz
Config 1
Config 2
x
z
y
F
z
Mesh depending Spot Weld Model
Mesh depending Spot Weld Model
Process of Spotweld Assessment with FEMFAT
1. Original FE-Model 2. Automatic
Preprocessing in
FEMFAT
4. Nastran Calculation
5. Fatigue
Assessement with
FEMFAT
6. Fatigue Results
3. FEMFAT Spot Model
Mesh Depending Creation of Spot Weld Model
Node C300
(Color or Coordinate
System)
Beam Element
Mesh Depending Creation of Spot Weld Model
Shell Elements
for Evaluation
Node C300
Welding Seam
Node C120
Local Coordinate System
Mesh Independent
Mesh Independent
Spot Weld Model
Spot Weld Model
FEMFAT SPOT Mesh Indipendent Preprocessing
Automatically Created Model of Spot Weld
Spot Location is defined by Control File created in the CAD World
Coordinates of the
spot joint from CDH-
control file
New position of the
center SPOT Node
and of the connecting
beam.
First step:
The center SPOT nodes and the connecting beams will be defined
The FE-Structure after
Mesh Refinement
Second step:
Mesh refinement by applying the same procedure as for the mesh-
dependent preprocessing
FEMFAT SPOT Preprocessor
Experimental S/N-Curves
Material :St05
R =0.1
d =5 mm
s1 =0.75 mm
s2 =1.5 mm
L
o
a
d
a
m
p
l
i
t
u
d
e
[
N
]
F
F
Fgeelement
Scherzug
0
Kopfzug
90
F
F
F
F
15
30
45
60
75
F
F
Fgeelement
Scherzug
0
Kopfzug
90
F
F
F
F
15
30
45
60
75
Cross-tension load
J oint
Shear load
0
15
45
90
Local Stress Distribution for Pure External Tension Loading
radial stress
-200
shell top
shell bottom
-150
-100
-50
0
50
100
150
200
1 2 3 4 5 6 7 8
node number
shell top
shell bottom
tangential stress
-100
-50
0
50
100
150
1 2 3 4 5 6 7 8
node number
shell top
shell bottom
shear stress
-0,8
-0,6
-0,4
-0,2
0
0,2
0,4
0,6
0,8
1 2 3 4 5 6 7 8
node number
radial stress
-30
-20
-10
0
10
20
30
1 2 3 4 5 6 7 8
node number
shell top
shell bottom
tangential stress
-15
-10
-5
0
5
10
15
1 2 3 4 5 6 7 8
node number
shell top
shell bottom
shear stress
-15
-10
-5
0
5
10
15
1 2 3 4 5 6 7 8
node number
shell top
shell bottom
Local Stress Distribution for Pure External Shear Loading
Fatigue Simulation of a Back Door
Fatigue Test 10.000 Cycles
FEMFAT 9.200 Cycles
FE - Model
Fatigue Simulation of a Transmission Mount
Test: 230 000 Cycles
FEMFAT: 155 000 Cycles
Analytical SPOT Joint Model JSAE
x
y
z
F
x
F
y
F
z
M
x
M
y
M
z
D
d
Stiff nugget
Completely fixed boundary
2 2
3
2
1
1
ln
t
D
d
d
D
C
P
2 2
2
6
1
1
t d
D
d
D
d
C
B

t d
C
S

=
1
t d
C
T

=
2
2
( ) ( ) sin cos sin cos + + + =

y x S x y B z P sum r
F F C M M C F C
sum r sum

=
( )
T T y x S sum r
M C F F C =

cos sin
CBAR or CBEAM
CBAR, CBEAM, RBE2 or
RBE3
CBAR or CBEAM
Possible Definitions of Spot Joints
Spot Connections can be represented by
1. CBARs or CBEAMs only (direct connections)
2. CBARs or CBEAMs connected by RBE2, RBE3, CBAR or
CBEAM elements (indirect connection)
New GUI SPOT - Option
Three Options:
1. Combined Concept
2. Stress Concept
3. Force Concept
New Spot-Database 45
SPOT results based on beam forces
FEMFAT STRAIN
FEMFAT STRAIN
A Module for
Calculating the Fatigue Behaviour at Strain
Gauges Applicated on the Real Structure Based on
Measured Strain-Time-Histories Under Usage of the
Full Functionality of FEMFAT (Influence
Factors, Analysis Parameters, ...).
Calibrating the Stress Behaviour of Your FE-Model
with the Stress Behaviour of the Real Structure Under
Static Test Loading Using Virtual Software Strain Gauges
Defined in the FE-Model.
R-SG 1
L-SG 1
x
y
z
L-SG 4
x
y
z
L-SG 3
x
y
z
L-SG 2
z
x
y
FEMFAT STRAI N
Output:
Damage Value or Safety Factor
Against Endurance Limit and
Corresponding Local S/N Curve
for Each Defined SG
Strain-Time-Histories at
Strain Gauges (SGs)
SG 1
SG 2
SG 3
SG N
.
.
.
1
(t)
2
(t)
3
(t)
(t)
Material Properties
Stress Gradient
Mean Stress Influence
Technological Influences
Size Influence
Temperature Influence
Plastic Deformations
Influence Factors
Specimen S/N Curve
S
N
Component on the Test Bench
Material Strength Data
No FE-Model of the
Component is Required
+
+
FEMFAT
STRAI N/CALC
Requirements for FEMFAT STRAI N/CALC
FEMFAT
STRAI N/COMP
Component on the Test Bench
Measured Static Strain for
Each Reference Strain Gauge
i
(t)
SG 1
SG 2
SG 3
SG 4
SG N ...
Number
of SG
Calculated Static Stress for
Each Virtual Strain Gauge
i
(t)
SG 1
SG 2
SG 3
SG 4
SG N
...
Number
of SG
FE-Model from the Component
SG 1
Component under Static Loading
Specimen S/N Curve
Influence Factors
SG 1
Requirements for FEMFAT STRAI N/COMP
FEMFAT FEDIS
FEMFAT FEDIS
FEMFAT FEDI S
Automatically generating displacement
boundary conditions for nonmatching
mesh
No limitations on the element type
(volume, shell, beam, rod)
Volume element submodelling from results of
shell or beam models without additional modelling
Efficient submodelling for typical detailed stress
analysis with leading FEM systems
(I-DEAS, NASTRAN, PATRAN, ...)
=161 N/mm
Top=152 N/mm
=218 N/mm
Top=127 N/mm
SF endu=2.1
SF endu=1.34
SF endu=2.7
SF endu=1.82
Stress
Coarse
Stress
FEDI S
Safety
Factors
Coarse
Safety
Factors
FEDI S
FEMFAT FEDI S
Submodel
FEMFAT-FEDI S: Submodel of a Con-Rod
FEMFAT: Endurance Safety
Test: Failure at Con-Rod after 200 000 to 2.2
Mill. Cycles (different loading)
1.0
1.1
FE-model pump housing Detailed view
BOSCH / Volkswagen Diesel Unit Injector TDI
Stress distribution Submodel for hot spot
Trend analyses with various rounding radii
NEW FEATURES OF
NEW FEATURES OF
FEMFAT 4.5 & 4.6
FEMFAT 4.5 & 4.6
FEMFAT 4.5 New Features
3D-Visualization of finite element structure and FEMFAT-results
New method for spot joint analysis by assessment of beam forces according J SAE
New method for thermo-mechanical fatigue according Sehitoglu
Input and conversion of strain data (E/N-curves)
Re-import of FEMFAT-results and export in an arbitrary format
Additional result outputs (S/N-curves, influence factors, critical plane directions)
Isothermal temperature influence on static material parameters according German FKM
guideline (affecting Haigh-diagram)
General user defined isothermal temperature influence for 10 material parameters
General user defined Haigh-diagram (up to 50 points)
Group export / import as Hypermesh-like Nastran Bulk Data file
Improved WELD-method in FEMFAT-MAX (following FEMFAT-BASIC)
Minimization of element size influence of WELD-elements
Supporting new ANSYS elements 180-188 including pyramids and plain elements
Implementation of new equivalent stresses in FEMFAT-MAX (signed Mises) to accelerate
fatigue analysis
Material generator supports compacted graphite iron CGI
Import of nodal stresses
Determination of Critical Loadcasein ChannelMAX
Boundary layer model
MAX: Excel-like channel definition table
Damage equivalent reduction of load histories
Improvement of analysis filter
Visualization of cyclic stress/strain curve
New femfat.ini dialog
Extension WELD for laser welds
Extension WELD for Eurocode 3 und BS 7608
F-SPOT: Extension for CWELD and CHEXA
New method for plastic strain influence
New BASIC and MAX equivalent stresses
Derivation of Sehitoglu parameters with Maple
Plotting and Real Time Animation of FE stresses with FEMFAT VISUALIZER
ABAQUS ODB 6.5 interface including HP
Selection of parts from ABAQUS ODB
ABAQUS ODB interface for effective plastic strain
ANSYS RST interface for stresses
LS-DYNA interface for stresses
nCode DAC interface
IBM 64bit version
WELD: Stress correction at weld ends
WELD: Stress correction in TransMAX
FEMFAT 4.6 New Features

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May 13th 2005 femfat.support@ecs.steyr.com 1 www.femfat.

Influence of Stress Gradient to the Fatigue Strength

Mean stress effect in FEMFAT BASIC

Influence of Surface Treatment

Influence from Forming Simulation since V4.4

May 13th 2005 femfat.support@ecs.steyr.com 97 www.femfat.com

May 13th 2005 femfat.support@ecs.steyr.com 103 www.femfat.com

May 13th 2005 femfat.support@ecs.steyr.com 105 www.femfat.com

May 13th 2005 femfat.support@ecs.steyr.com 132 www.femfat.com

##This formula is still used for middle of welding seam !

( ) ( ) sin cos sin cos + + + =

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