ANSYS nCode DesignLife for 13.

0 ANSYS Workbench

Jeff Mentley HBM-nCode

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Agenda
Introduction What is Fatigue and Why is it important Approaches for Fatigue ANSYS nCode DesignLife overview What is new for ANSYS 13.0 DesignLife SP1 Questions

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ANSYS nCode DesignLife

Integrated within ANSYS Workbench 13 to provide a leading solution for advanced fatigue analysis.

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What is Fatigue?
Fatigue is:
Fa i l u r e u n d e r a r e p e at e d o r ot herw ise var ying load w h i c h n eve r r e a c h e s a l eve l suf fic ient t o c ause failure in a s i n g l e a p p l i c at i o n . T h e i n i t i at i o n a n d g r ow t h o f a c r a c k , o r g r ow t h o f a p r e ex i s t i n g d e fe c t , u n t i l it r e a c h e s a c r i t i c a l s i ze. The progressive and localized structural damage that occurs when a material is subjected to cyclic loading.
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Stress

Strain

Stress

Time

Early Failures

1808 Trevithick's Catch-me-who-can

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Present Day Fatigue Failure

1999 ICE high-speed trail derailed at Eschede, Germany

Hit bridge pillar - 100 k illed Ea r l y w h e e l d e s i g n c a u s e d v i b r at i o n s New w heel design Based upon st reet c ar design N o t t e s t e d at h i g h s p e e d b e fo r e s e r v i c e Co m p l e t e p r o t o t y p e s n eve r t est ed Cr a s h f i n d i n g s Ca u s e d b y c r a c k i n w h e e l Dy n a m i c , r e p e t i t i ve fo r c e s h a d n o t b e e n a c c o u n t e d fo r in design De s i g n l a c k e d a n a d e q u at e

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Why is it Important ?
Why do we need to do Fatigue Analysis? ...Between 80 - 90% of all structural failures

occur through a fatigue mechanism ...The estimated annual cost of fracture and fatigue to the US was 4.4% of GDP

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The Economic Effects of Fracture in the United States, National Bureau of Standards, U.S. Department of Commerce, Gaithersburg, MD, Special Publication 647-2, 1983.

Fatigue Analysis Process

Loading Environment

Geometry

Fatigue Analysis Stress-life Strain-life Crack growth

Life Fatigue is a statistical, not deterministic, phenomenon.

Material Properties

Post-processing optimization
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SN is also known as High Cycle Fatigue or Nominal Stress Approach Elastic stress history used to determine life May be applied to either material or component Used extensively for welded joints and nonmetallics Suitable for lives greater than 1e4 cycles Well established, Familiar, Large amount of material data available, Simple loadings can be analyzed as a hand calc. 2011 ANSYS, Inc. 8/29/11

Fatigue Analysis: Stress-Life (SN)

Whler circa 1850

Stress, centners/zoll2

800 600
Smooth shoulder

400
Sharp shoulder

200 104 105 Cycles, N 106

Fatigue Analysis: Strain-Life (EN)

EN is also known as Low Cycle Fatigue, Crack Initiation or Local Strain Approach Elasto-plastic strain history used to determine life Local plasticity can be estimated from fully elastic FE analysis or computed directly in ANSYS Suitable for low and high cycle fatigue
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Plastic (Low Cycle Fatigue Line)

Elastic (High Cycle Fatigue Line)

Cycle counting and 8/29/11

Fatigue Analysis: Crack Growth

Crack growth known as crack propagation, or fracture mechanics Predicts cycle by cycle crack growth Used in aerospace Damage Tolerance analysis Determine impact of known or suspected flaws
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Crack

ANSYS nCode DesignLife

ANSYS Workbench

Engineering Data
Materials Loads DesignLife

Stresses

Mechanical

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ANSYS nCode DesignLife

n Co d e OEM Pa r t n e r s h i p n Co d e De s i g n L i fe A d v a n c e d Fat i g u e Analysis Pr o c e s s Or i e n t at i o n Ea s e o f U s e Wo r k b e n c h I n t e g r at i o n De s i g n L i fe Sy s t e m s De s i g n Pa r a m e t e r s M at e r i a l l i b r a r y

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ANSYS nCode DesignLife Features Streamlining-the Virtual

Engineering Process

Powerful Fatigue Analysis Technology Integrated Reporting and Process Encapsulation Fast, Expandable, and Scalable

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Intuitive and easy to use software fo r p e r fo r m i n g f at i g u e a n a l y s i s o f f i n i t e elem ent m odels.

ANSYS nCode DesignLife - Features

Efficiently analyze l a r g e f i n i t e elem ent m odels and c om plet e usage sc hedules. Wide range of fatigue analysis capabilities i n c l u d i n g s t r e s s l i fe , s t r a i n -l i fe , m u l t i -a x i a l, w eld analysis, vir t ual shaker t able, and m ore. Single environment fo r b o t h Te s t a n d CA E d at a . Ex t e n s i ve material database
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SYS nCode DesignLife has an extensive scope of fatigue capabilities

ANSYS nCode DesignLife Capabilities

Fi n i t e El e m e n t r e s u l t s suppor t ed St at i c (l i n e a r super posit ion) Tr a n s i e n t Cr a c k Gr ow t h (L EFM ) Modal Se a m w e l d s a n d s p o t w e l d s Fr e q u e n c y Re s p o n s e H i g h t e m p e r at u r e f at i g u e L i n e a r & N o n -l i n e a r V i b r at i o n f at i g u e (s h a k e r s i m u l at i o n ) Fi n i t e El e m e n t s o l ve r s V i r t u a l St r a i n g a g e suppor t ed Co m p l e t e d u t y c yc l e s / f l i g ht A N SYS spec t r um s Abaqus Mult iple r uns in a single analysis Nast ran M u l t i -p r o c e s s o r e n a b l e d fo r f a st L S-Dy n a 16 2011 ANSYS, Inc. 8/29/11 result s St r a i n -L i fe (a u t o m at e d m u l t i -a x i a l c or rec t ions) St r e s s -L i fe (s i n g l e , m u l t i -c u r ve, Haigh diagram s)

ANSYS nCode DesignLife - Benefits Pe r fo r m v i r t u a l d u r a b i l i t y a s s e s s m e n t u p f r o n t t o

r e d u c e r e l i a n c e o n p h y s i c a l t e s t a n d avo i d c o s t l y design and t ooling c hanges Pe r fo r m s m a r t e r a n d q u i c k e r p h y s i c a l t e s t s b y s i m u l at i n g f i r s t De s i g n d u r a b i l i t y i n t o yo u r p r o d u c t s a n d r e d u c e w ar rant y c laim s St a n d a r d i ze a n a l y s i s p r o c e s s e s t o i m p r ove c onsist enc y and qualit y A u t o m at e p r o c e s s e s t o b e t t e r u t i l i ze e n g i n e e r s t im e and w or k load Assess m ore design opt ions, c onsider m ore realist ic loading c ondit ions and m ore c onfident ly reduc e c ost and w eight
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ANSYS 13 nCode DesignLife SP1

Support for Named Selections New state engine to manage DesignLife system
updates DesignLife processes saved with results FKM mean stress with multicurve SN Material map import deactivate Seam weld enhancements BS7608 and Eurocode 3 weld analysis

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ANSYS nCode DesignLife

Questions

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ANSYS nCode DesignLife

Jeff Mentley HBM - nCode Tel: +1.248.945.4368 jeff.mentley@ncode.com Ray Browell ANSYS, Inc. Tel: +1.724.514.3070 Ray.Browell@ansys.com

Thank you!

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