FEMFAT Version 5.

0 News
Christian Gaier
April 2011

FEMFAT 5.0 Top Features

Modernized GUI

FEMFAT SPECTRAL

BREAK for MAX

Extended WELD
Database

Pore Influence

3D-Presentation

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FEMFAT 5.0 More Features

Methods
BASIC: PLAST-module extended for Mises-stress
BASIC: Definition of cutting plane angle
BASIC: New default setting Scaled normal stress for all materials
except gray cast iron
BASIC & MAX: Parameters of technological size influence can be
defined in userdefparam.dbs
WELD: Sensitivity analysis for process influences of welding seams
SPOT force based: Diameter and material from connected sheets

VISUALIZER
Display groups of weld seams of same type
Set color and line thickness for welding seams

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FEMFAT 5.0 Even more Features

Interfaces
ABAQUS ODB interface: Import of increment 0
(e.g. from POST OUTPUT)
ABAQUS ODB interface: Import of shell thicknesses from forming
simulation
Mapping of FEMFAT nodal results to elements and export to HyperMesh
Output rainflow matrix data as CSV-file

Handling

Definition of path to WELD and SPOT database in femfat.ini

FEMFAT is able to start a virtual display in batch mode (by using Xvfb)
Output of survival probability
Select group by name
FEMFAT can be started several times in one working directory
SPOT: Definition of dependency of fatigue limit on ultimate strength by
a polygonal line
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New FEMFAT 5.0 GUI Layout

FEMFAT 4.8

FEMFAT 5.0

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New FEMFAT 5.0 GUI Layout

FEMFAT 4.8

FEMFAT 5.0

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New FEMFAT 5.0 GUI Layout

FEMFAT 4.8

FEMFAT 5.0

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New FEMFAT 5.0 GUI Layout

FEMFAT 4.8

FEMFAT 5.0

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New FEMFAT 5.0 GUI Layout

FEMFAT 4.8

FEMFAT 5.0

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Multiaxial Fatigue Analysis of Stochastically Loaded

Mechanical Systems
Advantages:
- Effective numerical analysis
- Fatigue analysis based on unit loads in
frequency domain
Spectral fatigue analysis

- Multiaxial PSDs possible

New theoretical and practical

aspects:
- Material-characteristic equivalent
stresses in frequency domain

Critical cutting plane method

- Different technological influences, e.g.

notch support effect

S2( )

ai a j

*
i

i, j I

- Consideration of constant stresses

- Amplitude distribution models:

- Raleigh
- Dirlik

xx, yy, zz, xy, xz, yz

Autocorrelation

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10

Effect of Porosity on Fatigue Life

Stress Amplitude

AlSi9Cu3, die cast, R=-1, Kt=1.0, RT

40% Decrease
Very large scatter

By courtesy of
Christian Oberwinkler,
AMB Leoben

Without pores
With pores

Number of cycles

Tests performed at University of Leoben show, that porosity is not suitable

for fatigue life prediction because of extremely large scatter!
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11

Crack Initation at Pores

Cracks initiate at pores with maximum size
Methods of fracture mechanics are suitable

Initial crack length dequ

dequ

Crack propagation

By courtesy of Christian Oberwinkler, AMB Leoben

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12

Kitagawa-Takahashi Diagram

AlSi9Cu3, die cast, R=-1, N=1e7

Crack propagation
Stress Amplitude [Mpa]

Pore free material

Sa

K th
2Y

a a0

No crack propagation
No rupture
Rupture
El-Haddad
Kitagawa

Equivalent diameter [mm]

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13

Determination of Threshold of Stress Intensity Factor

No crack
propagation

Threshold value

Crack propagation rate da/dN [nm/cyc]

AlSi9Cu3, die cast, Single Edge Bending

Crack propagation

Stress intensity K [Mpa m]

Y S

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14

Recalculate Material Parameters for Given Defect

Size (e.g. Pores)
2.)
3.)

1.)
4.)
5.)

Generation of
material data for
FEMFAT boundary
layer model

6.)
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15

Predefined Defect Geometries

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16

BREAK for MAX

Calculate static safety factor
at each time point
Output of minimum static
safety factor and
corresponding time step
Equivalent stress selection
(BASIC & MAX):
Automatic:

Max./Min. Principal Stress

for gray cast iron
Von Mises for all other
materials

Von Mises
Max./Min. Principal Stress

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17

Extension of WELD Database for Shear Data

Polygonal Line for shear notch fatigue limit:
$ SX .... mark for shear fatigue limits of base material
$ SY .... mark for allowable shear notch fatigue strength of welding seam
$
$
ST37
ST52 QSTE690
$|--(1)--|--(2)--|--(3)--|--(4)--|--(5)--|--(6)--|--(7)--|--(8)--|--(9)--|
SX
0.0
100.0
160.0
200.0 5000.0
SY
0.0
141.0
156.0
159.0
159.0

Identifier: SX, SY
As default setting, values
from normal notch fatigue
strength reduced by 1.41 are
used.

Haigh-Diagrams for shear stress:

$ 2|-(3)-|-(4)-|-(5)-|-(6)-|-(7)-|-(8)-|-(9)-|-(10)|-(11)|-(12)|-(13)|-(14)|
$
| A | B | C | W1 | D | E | F | W2 | K1 | K2 | R1 | R2 |
SH 1 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85
SH 2 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85
SH 3 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85
SH 4 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85
SH 5 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85
SH 6 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85
SH 7 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85
SH 8 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85
SH 9 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85
SH10 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0
1.0 15.0 0.26 3.85

Identifier: SH

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The shear Haigh-diagrams

are constructed in the same
way as the Haigh-diagrams
for normal stress.

18

Extension of WELD Database for Shear Data

Notch factors
for shear stresses for each joint type for TOP and
BOTTOM side (identifiers SSTO, SSBO):
Welding seam middle nodes:
$ Data for nodes in the middle of the weld seam
$
$
MNT MNB UTL1 UTL2 UTL3 UBL1 UBL2 UBL3 WTL1 WTL2 WTL3 WBL1 WBL2 WBL3 SPTO SPBO SSTO SSBO
$
--------------------------------------------------------------------------------------109
1.70 1.96
7.23 3.64
3.98 3.98
110
1.70 1.96
7.23 3.64
3.98 3.98
111
1.70 1.96
7.23 3.64
3.98 3.98
112
1.70 1.96
7.23 3.64
3.98 3.98

Welding seam begin/end nodes:

If fields are empty:

$ Data for a node at the weld seam end or begin

$
$ NCOL MAT MNT MNB UTL1 UTL2 UTL3 UBL1 UBL2 UBL3 WTL1 WTL2 WTL3 WBL1 WBL2 WBL3 SPTO SPBO SSTO SSBO
$------------------------------------------------------------------------------------------------CO101 109
3.06 3.00
1.96 1.66
1.90 3.76 3.98 3.98
CO102 109
3.06 3.00
1.96 1.66
2.71 2.63 3.98 3.98
CO106 109
3.06 3.00
1.96 1.66
1.90 3.76 3.98 3.98
CO107 109
3.06 3.00
1.96 1.66
2.71 2.63 3.98 3.98

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19

Extension of WELD Database for Shear Data

S-N curves for shear stresses for each joint type for TOP und BOTTOM side
Welding seam middle nodes:
$
BEPKT 1
BEPKT 2
BEPKT 3
BEPKT 4
SHEAR Top
SHEAR Bottom
$
Inclination
Inclination
Inclination
Inclination
Inclination
Inclination
Survival Probability in Perc.
$
Cycle Endur.
Cycle Endur.
Cycle Endur.
Cycle Endur.
Cycle Endur.
Cycle Endur. Range of Disp. 10-90 Percent
$
----------------------------------------------------------------------------------------------------------------------N109
5.00
5.00
4.00
4.00
5.00
5.00
If fields are empty, data of
E109
1800000
1800000
1000000
1000000
2000000
2000000
N110
5.00
5.00
4.00
4.00
5.00
5.00
normal stress S-N curves
E110
1800000
1800000
1000000
1000000
2000000
2000000
are used, or shear stress
N111
5.00
5.00
4.00
4.00
5.00
5.00
S-N curve of EUROCODE 3
E111
1800000
1800000
1000000
1000000
2000000
2000000
database if available.
N112
5.00
5.00
4.00
4.00
5.00
5.00
E112
1800000
1800000
1000000
1000000
2000000
2000000

Welding seam begin/end nodes:

$ NCOL MAT
BEPKT 1
BEPKT 2
BEPKT 3
BEPKT 4
SHEAR Top
SHEAR Bottom
$
Inclination
Inclination
Inclination
Inclination
Inclination
Inclination
Survival Probability
$
Cycle Endur.
Cycle Endur.
Cycle Endur.
Cycle Endur.
Cycle Endur.
Cycle Endur. Range of Disp. 10-90
$-----------------------------------------------------------------------------------------------------------------------CN101 109
5.00
5.00
5.00
5.00
5.00
5.00
97.7
CE101 109
1800000
1800000
1800000
1800000
2000000
2000000
1.297
CN102 109
5.00
5.00
5.00
5.00
5.00
5.00
97.7
CE102 109
1800000
1800000
1800000
1800000
2000000
2000000
1.297
CN106 109
5.00
5.00
5.00
5.00
5.00
5.00
97.7
CE106 109
1800000
1800000
1800000
1800000
2000000
2000000
1.297
CN107 109
5.00
5.00
5.00
5.00
5.00
5.00
97.7
CE107 109
1800000
1800000
1800000
1800000
2000000
2000000
1.297

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20

Generate 3D-Presentation for Powerpoint

Displayed result, group and color bar can be
exported as VTFx-file ( Ceetron)

Free Powerpoint-plugin from Ceetron

available (GLview3DPluginSetup.exe)

Start
presentation
Insert a frame and
load VTFx-file
Also node description can
be displayed
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21

Stress

BASIC: PLAST-module extended for Mises-stress

Max
Max
Modified

Mean
Mean
Modified

Strain

Min
Min
Modified

Richard Edler von Mises

1883-1953
Austrian mathematician
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22

BASIC: Definition of Cutting Plane Angle

Same cutting planes as

in MAX with 3D-option

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23

BASIC:
New Default Setting for Equivalent Stress
Now the option Automatic works in the
same way for BASIC and MAX:
For all materials except gray cast iron:
4.8: Mod. Equivalent Stress in Critical Plane
5.0: Scaled Normal Stress in Critical Plane

For gray cast iron:

4.8 & 5.0: Normal Stress in Critical Plane
Equivalent torsion mean stresses in planes:

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24

Sensitivity analysis for process influences of

welding seams
Example: Influence of weld penetration degree for 45 T-joint:

Root notch factor

= 10,0

= 6,7

= 5,0

For these process parameter WELD database

for best & worst case are provided:

penetration degree
gap
seam thickness
seam inclination angle

FEMFAT WELD solution:

= d1 / d2
g
a

FEMFAT ffj-templates are provided for automatic sensitivity analysis.

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d1
d2
25

SPOT force based: Diameter and material from

connected sheets
Diameter = Factor*root(sheet Thickness)
Diameter is taken from property card or
CHEXA cross-section
Take material from connected shell
element

Take material from connector element

(beam, CWELD, CHEXA)

Output of material in pro-file:

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26

VISUALIZER:
Display groups of weld seams of same type

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27

VISUALIZER:
Display groups of weld seams of same type
Display all T-joints

Display all overlap joints

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28

ABAQUS interface: Import of increment 0 (e.g. from POST

OUTPUT) and shell thicknesses from forming simulation

Author:

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29

Mapping of FEMFAT nodal results to elements

and export to HyperMesh
Display of element results in HyperMesh

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30

Output Rainflow Matrix Data as CSV-File

Import and display

in Excel

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31

Output of Survival Probability

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32

Definition of Path to WELD and SPOT Database in

femfat.ini

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33

Select Group by Name

Possible FEMFAT Job-file (.ffj) commands for group selection:
setValue {} {} GUI_Group:Group 10
select by label
setValue {} {} GUI_Group:Group {10 Group_Name} select by label
setValue {} {} GUI_Group:Group {Group_Name}
select by name

If there are several groups with same name, the first one will be
selected.

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34

Platform Strategy for FEMFAT 5.0

Supported hardware platforms:

Intel 686, AMD-K7 32bit

AMD 64, Intel 64 64bit
AMD 64, Intel 64 64bit
IBM Power 4-7
64bit

Windows Server 2003, XP, Vista, 7

Windows Server 2003/2008, XP, Vista, 7
Linux RHEL 4-6, Linux SLES 9-11
AIX 5.3, AIX 6.1

Other platforms (HP PA-Risc and Itanium2 under HP-UX/Linux) are

not supported anymore, because:
they are not widely distributed anymore
They display rather poor performance

If these plans do not conform to your requirements, please contact

us as soon as possible.

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35

The FEMFAT development team wish you

much success with

FEMFAT 5.0

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36