Professional Documents
Culture Documents
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
May 13th 2005 femfat.support@ecs.steyr.com 3 www.femfat.com
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
?
May 13th 2005 femfat.support@ecs.steyr.com 4 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 5 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 6 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 7 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 8 www.femfat.com
FEMFAT Results: femfat.dma
E.g. Safety Factors Against Endurance Limit
May 13th 2005 femfat.support@ecs.steyr.com 9 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 10 www.femfat.com
FEMFAT Results: femfat.msg
Error messages and warnings
that occur during the calculation
are stored in the *.msg file.
May 13th 2005 femfat.support@ecs.steyr.com 11 www.femfat.com
FEMFAT - Additional Analysis Outputs
Computed S/N Curve
Specimen S/N Curve
May 13th 2005 femfat.support@ecs.steyr.com 12 www.femfat.com
FEMFAT - Additional Analysis Outputs
Modified Haigh Diagram
Each point (
A,i
,
M,i
)
represent one
cutting plane.
Original Haigh Diagram
May 13th 2005 femfat.support@ecs.steyr.com 13 www.femfat.com
FEMFAT Results: Equivalent Stress History
May 13th 2005 femfat.support@ecs.steyr.com 14 www.femfat.com
FEMFAT Results: Damage History
Damage History
May 13th 2005 femfat.support@ecs.steyr.com 15 www.femfat.com
FEMFAT Online Manual
May 13th 2005 femfat.support@ecs.steyr.com 16 www.femfat.com
FEMFAT BASIC
FEMFAT BASIC
May 13th 2005 femfat.support@ecs.steyr.com 17 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 18 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 19 www.femfat.com
Import of Stresses: Two Variants
Choose Between Two
Variants
May 13th 2005 femfat.support@ecs.steyr.com 20 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 21 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 22 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 23 www.femfat.com
Crack Location in Test
Minimum Endurance Safety
Mass Balance Unit
Comparison of FEMFAT to Test Results
May 13th 2005 femfat.support@ecs.steyr.com 24 www.femfat.com
Test: 400 000 Cycles
FEMFAT: 300 000 Cycles
Clutch Shaft
Comparison of FEMFAT to Test Results
May 13th 2005 femfat.support@ecs.steyr.com 25 www.femfat.com
Run FEMFAT with Parameter
Run FEMFAT with Parameter
-
-
ini
ini
May 13th 2005 femfat.support@ecs.steyr.com 26 www.femfat.com
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.
May 13th 2005 femfat.support@ecs.steyr.com 27 www.femfat.com
Handling Memory with FEMFAT
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.
May 13th 2005 femfat.support@ecs.steyr.com 28 www.femfat.com
Handling Memory with FEMFAT
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.
May 13th 2005 femfat.support@ecs.steyr.com 29 www.femfat.com
Run FEMFAT As A Batch Job
Run FEMFAT As A Batch Job
May 13th 2005 femfat.support@ecs.steyr.com 30 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 31 www.femfat.com
# 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
May 13th 2005 femfat.support@ecs.steyr.com 32 www.femfat.com
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
Your FEMFAT installation path/bin/bin/femfat.tcl -job=piston_2.ffj
Your FEMFAT installation path/bin/bin/femfat.tcl -job=piston_3.ffj
Your FEMFAT installation path/bin/bin/femfat.tcl -job=piston_4.ffj
Your FEMFAT installation path/bin/bin/femfat.tcl -job=piston_5.ffj
Your FEMFAT installation path/bin/bin/femfat.tcl -job=piston_6.ffj
Your FEMFAT installation path/bin/bin/femfat.tcl -job=piston_7.ffj
Your FEMFAT installation path/bin/bin/femfat.tcl -job=piston_8.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
May 13th 2005 femfat.support@ecs.steyr.com 33 www.femfat.com
THEORETICAL BACKGROUND
THEORETICAL BACKGROUND
NOTCH INFLUENCE
NOTCH INFLUENCE
May 13th 2005 femfat.support@ecs.steyr.com 34 www.femfat.com
According W. Schuetz, 1968, Germany
Fatigue Strength of Steels
K
= stress concentration factor
R = -1 alternating
Increasing UTS and price
May 13th 2005 femfat.support@ecs.steyr.com 35 www.femfat.com
Power Flow
Stress Distribution
Stress Concentration
May 13th 2005 femfat.support@ecs.steyr.com 36 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 37 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 38 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 39 www.femfat.com
endurance
stress
a Bending
M M
Relative Stress Gradient
Tension / Compression
alt TC
=0
a Tens / Comp
=0
F F
( )
( )
v
v
TC alt Bending alt
enDur G
b
f '
2
1
1
+ =
May 13th 2005 femfat.support@ecs.steyr.com 40 www.femfat.com
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
Influence of Stress Gradient to the Fatigue Strength
Relative Stress Gradient
according to FEMFAT / Eichlseder
May 13th 2005 femfat.support@ecs.steyr.com 41 www.femfat.com
Influence of Stress Gradient to the Fatigue Strength
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
May 13th 2005 femfat.support@ecs.steyr.com 42 www.femfat.com
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
r el. st r ess gr adient
'
k
C
,
G
R
/
k
M
St37
St52
42CrMo4
GS40
GGG40
GG25
AlSi10Mg
Relative Stress Gradient
Influence of Relative Stress Gradient to the Inclination
according to Hck, Thrainer, Schtz
May 13th 2005 femfat.support@ecs.steyr.com 43 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 44 www.femfat.com
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
r el. st r ess gr adient
'
f
G
R
,
c
f
St37
St52
42CrMo4
GS40
GGG40
GG25
AlSi10Mg
Relative Stress Gradient
Influence of Stress Gradient to the S/N Curve Cycle Limit
according to Hck, Thrainer, Schtz
May 13th 2005 femfat.support@ecs.steyr.com 45 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 46 www.femfat.com
MEAN STRESS INFLUENCE
MEAN STRESS INFLUENCE
CRITICAL PLANE APPROACH
CRITICAL PLANE APPROACH
May 13th 2005 femfat.support@ecs.steyr.com 47 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 48 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 49 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 50 www.femfat.com
a n
m n
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 ( )
May 13th 2005 femfat.support@ecs.steyr.com 51 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 52 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 53 www.femfat.com
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.
May 13th 2005 femfat.support@ecs.steyr.com 54 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 55 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 56 www.femfat.com
Modified Haigh Diagram
Modified Haigh Diagram
May 13th 2005 femfat.support@ecs.steyr.com 57 www.femfat.com
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
Modified Haigh Diagram
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.
May 13th 2005 femfat.support@ecs.steyr.com 58 www.femfat.com
Palmgren Miner
Palmgren Miner
May 13th 2005 femfat.support@ecs.steyr.com 59 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 60 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 61 www.femfat.com
Safety Factor Analyze
Safety Factor Analyze
May 13th 2005 femfat.support@ecs.steyr.com 62 www.femfat.com
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
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TEMPERATUR INFLUENCE
TEMPERATUR INFLUENCE
May 13th 2005 femfat.support@ecs.steyr.com 64 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 65 www.femfat.com
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)
May 13th 2005 femfat.support@ecs.steyr.com 66 www.femfat.com
Reading in Temperature Fields
4. Go to Influence
Factors
5. Activate the
Isothermal
Temperature
Influence
May 13th 2005 femfat.support@ecs.steyr.com 67 www.femfat.com
FEMFAT Isothermal Temperature Influence
Log (Load Cycles)
Log (Stress Amplitude)
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.
May 13th 2005 femfat.support@ecs.steyr.com 68 www.femfat.com
OTHER INFLUENCES
OTHER INFLUENCES
May 13th 2005 femfat.support@ecs.steyr.com 69 www.femfat.com
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
+
+
=
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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
=
2
0
1
2
0
1
2
0
1
ln ln ln
3
2
h
h
b
b
l
l
V
+
+
=
May 13th 2005 femfat.support@ecs.steyr.com 85 www.femfat.com
Combination of Influence Factors
N Parameter of the material
Influences to the Cycle Limit
Combination according TGL 19340 / FKM 94
k
M
Inclination of the component S/N curve at alternating load (R=-1)
IFK3 Parameter of the material
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
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FEMFAT PLAST
FEMFAT PLAST
May 13th 2005 femfat.support@ecs.steyr.com 87 www.femfat.com
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
)
May 13th 2005 femfat.support@ecs.steyr.com 88 www.femfat.com
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
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FEMFAT BREAK
FEMFAT BREAK
May 13th 2005 femfat.support@ecs.steyr.com 90 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 91 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 92 www.femfat.com
Housing
Nonlinear contact,
radial, axial
Shaft
Nonlinear contact,
conical
Outer bearing ring
Detail:
Taper Roller
Static Safety Factors
FEMFAT BREAK Gearbox analysis
Equivalent Stress
May 13th 2005 femfat.support@ecs.steyr.com 93 www.femfat.com
FEMFAT MAX
FEMFAT MAX
May 13th 2005 femfat.support@ecs.steyr.com 94 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 95 www.femfat.com
Results
Damage Values
Endurance Safety Factors
Life
FEMFAT CHANNEL MAX
Specimen Material Data
FEMFAT MAX
F
V
=
Channel 1
F
S
=
Channel 2
F
L
=
Channel 3
May 13th 2005 femfat.support@ecs.steyr.com 96 www.femfat.com
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
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
May 13th 2005 femfat.support@ecs.steyr.com 99 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 100 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 101 www.femfat.com
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)
May 13th 2005 femfat.support@ecs.steyr.com 102 www.femfat.com
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
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
May 13th 2005 femfat.support@ecs.steyr.com 104 www.femfat.com
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)
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
May 13th 2005 femfat.support@ecs.steyr.com 106 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 107 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 108 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 109 www.femfat.com
0 20 40 60 80 100 120 140 160 180
maximum equivalent stress for channel 1
maximum equivalent stress for channel 2
maximum equivalent stress for channel 3
upper equivalent stress
filter limits
selected planes
Example with 3 Channels
Critical Plane Filter Method 1
May 13th 2005 femfat.support@ecs.steyr.com 110 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 111 www.femfat.com
-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
May 13th 2005 femfat.support@ecs.steyr.com 112 www.femfat.com
FEMFAT Result
Damage Distribution
Comparison of FEMFAT to Test Results
May 13th 2005 femfat.support@ecs.steyr.com 113 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 114 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 115 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 116 www.femfat.com
THE MATERIAL GENERATOR
THE MATERIAL GENERATOR
May 13th 2005 femfat.support@ecs.steyr.com 117 www.femfat.com
Required Material Data for FEMFAT
May 13th 2005 femfat.support@ecs.steyr.com 118 www.femfat.com
Import of Material Properties from Database
Reading Various Materials from the Database
E.g. Aluminum for the block, Steel for Valve Seats,...
May 13th 2005 femfat.support@ecs.steyr.com 119 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 120 www.femfat.com
Using
Using
FEMFAT WELD
FEMFAT WELD
May 13th 2005 femfat.support@ecs.steyr.com 121 www.femfat.com
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
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Setup of FE Modell
For Example With Shell Elements
Corse Mesh
Analysis Process Step 1
May 13th 2005 femfat.support@ecs.steyr.com 123 www.femfat.com
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
Analysis Process Step 2
May 13th 2005 femfat.support@ecs.steyr.com 124 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 125 www.femfat.com
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.
May 13th 2005 femfat.support@ecs.steyr.com 126 www.femfat.com
Calculation of Stresses
Import of Stress Results into FEMFAT
Interfaces for Numerous Common File Formats
Stress at arc weld = 106 MPa
Analysis Process Step 3
Maximum Stress = 206 MPa
Base Material
May 13th 2005 femfat.support@ecs.steyr.com 127 www.femfat.com
Activating the Weld Influence
Activate FEMFAT
Weld as Influence
Factor
May 13th 2005 femfat.support@ecs.steyr.com 128 www.femfat.com
Analysis Process Step 4
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)
May 13th 2005 femfat.support@ecs.steyr.com 129 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 130 www.femfat.com
Analysis
Analysis
Process
Process
of
of
FEMFAT WELD
FEMFAT WELD
May 13th 2005 femfat.support@ecs.steyr.com 131 www.femfat.com
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
=
=
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
May 13th 2005 femfat.support@ecs.steyr.com 133 www.femfat.com
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
]
190
150
100
50
0 40 80 120
30 mm
5 mm
10 mm
20 mm
Singular Stress Behavior
May 13th 2005 femfat.support@ecs.steyr.com 150 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 151 www.femfat.com
Mesh depending Spot Weld Model
Mesh depending Spot Weld Model
May 13th 2005 femfat.support@ecs.steyr.com 152 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 153 www.femfat.com
Mesh Depending Creation of Spot Weld Model
Node C300
(Color or Coordinate
System)
Beam Element
May 13th 2005 femfat.support@ecs.steyr.com 154 www.femfat.com
Mesh Depending Creation of Spot Weld Model
Shell Elements
for Evaluation
Node C300
Welding Seam
Node C120
Local Coordinate System
May 13th 2005 femfat.support@ecs.steyr.com 155 www.femfat.com
Mesh Independent
Mesh Independent
Spot Weld Model
Spot Weld Model
May 13th 2005 femfat.support@ecs.steyr.com 156 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 157 www.femfat.com
New position of the
center SPOT Node
and of the connecting
beam.
FEMFAT SPOT Mesh Indipendent Preprocessing
First step:
The center SPOT nodes and the connecting beams will be defined
May 13th 2005 femfat.support@ecs.steyr.com 158 www.femfat.com
The FE-Structure after
Mesh Refinement
FEMFAT SPOT Mesh Indipendent Preprocessing
Second step:
Mesh refinement by applying the same procedure as for the mesh-
dependent preprocessing
May 13th 2005 femfat.support@ecs.steyr.com 159 www.femfat.com
FEMFAT SPOT Preprocessor
May 13th 2005 femfat.support@ecs.steyr.com 160 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 161 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 162 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 163 www.femfat.com
Fatigue Simulation of a Back Door
Fatigue Test 10.000 Cycles
FEMFAT 9.200 Cycles
FE - Model
May 13th 2005 femfat.support@ecs.steyr.com 164 www.femfat.com
Fatigue Simulation of a Transmission Mount
Test: 230 000 Cycles
FEMFAT: 155 000 Cycles
May 13th 2005 femfat.support@ecs.steyr.com 165 www.femfat.com
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
=
( )
T T y x S sum r
M C F F C =
cos sin
May 13th 2005 femfat.support@ecs.steyr.com 166 www.femfat.com
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)
May 13th 2005 femfat.support@ecs.steyr.com 167 www.femfat.com
New GUI SPOT - Option
Three Options:
1. Combined Concept
2. Stress Concept
3. Force Concept
New Spot-Database 45
May 13th 2005 femfat.support@ecs.steyr.com 168 www.femfat.com
SPOT results based on beam forces
May 13th 2005 femfat.support@ecs.steyr.com 169 www.femfat.com
FEMFAT STRAIN
FEMFAT STRAIN
May 13th 2005 femfat.support@ecs.steyr.com 170 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 171 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 172 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 173 www.femfat.com
FEMFAT FEDIS
FEMFAT FEDIS
May 13th 2005 femfat.support@ecs.steyr.com 174 www.femfat.com
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, ...)
May 13th 2005 femfat.support@ecs.steyr.com 175 www.femfat.com
=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
May 13th 2005 femfat.support@ecs.steyr.com 176 www.femfat.com
Submodel
FEMFAT-FEDI S: Submodel of a Con-Rod
May 13th 2005 femfat.support@ecs.steyr.com 177 www.femfat.com
Comparison of FEMFAT to Test Results
FEMFAT: Endurance Safety
Test: Failure at Con-Rod after 200 000 to 2.2
Mill. Cycles (different loading)
1.0
1.1
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FE-model pump housing Detailed view
BOSCH / Volkswagen Diesel Unit Injector TDI
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Stress distribution Submodel for hot spot
BOSCH / Volkswagen Diesel Unit Injector TDI
May 13th 2005 femfat.support@ecs.steyr.com 180 www.femfat.com
Trend analyses with various rounding radii
BOSCH / Volkswagen Diesel Unit Injector TDI
May 13th 2005 femfat.support@ecs.steyr.com 181 www.femfat.com
NEW FEATURES OF
NEW FEATURES OF
FEMFAT 4.5 & 4.6
FEMFAT 4.5 & 4.6
May 13th 2005 femfat.support@ecs.steyr.com 182 www.femfat.com
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
May 13th 2005 femfat.support@ecs.steyr.com 183 www.femfat.com
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