This document provides an overview of fatigue evaluation using ANSYS NCode DesignLife software. It describes the basics of fatigue analysis and the NCode DesignLife workflow. Key features of NCode DesignLife include defining material models, loading conditions, and performing fatigue calculations using glyphs connected in a workflow. An example is presented demonstrating a duty cycle fatigue analysis of a lever subjected to multiple loading classes using the NCode DesignLife tools.
This document provides an overview of fatigue evaluation using ANSYS NCode DesignLife software. It describes the basics of fatigue analysis and the NCode DesignLife workflow. Key features of NCode DesignLife include defining material models, loading conditions, and performing fatigue calculations using glyphs connected in a workflow. An example is presented demonstrating a duty cycle fatigue analysis of a lever subjected to multiple loading classes using the NCode DesignLife tools.
This document provides an overview of fatigue evaluation using ANSYS NCode DesignLife software. It describes the basics of fatigue analysis and the NCode DesignLife workflow. Key features of NCode DesignLife include defining material models, loading conditions, and performing fatigue calculations using glyphs connected in a workflow. An example is presented demonstrating a duty cycle fatigue analysis of a lever subjected to multiple loading classes using the NCode DesignLife tools.
DESIGNLIFE Short overview of fatigue Introduction to nCode Design Life products nCode Design Life basic procedure Main Glyph items Duty Cycle procedure example New features for nCode 6.0 OBJECTIVES To make it simple, fatigue is a special structural failure structural failure, due to crack growth caused by repeated loading cycles repeated loading cycles. Usually loads that result in fatigue failure cause stress levels that are below the yield stress limit of the material. In other words, a specific load magnitude may not cause failure in a not cause failure in a single application single application, but it may result in fatigue failure after several fatigue failure after several cycles cycles. FATIGUE ANALYSIS Why perform a fatigue analysis? Why perform a fatigue analysis? Cant the resistance to fatigue be estimated from a stress analysis? Sometimes it can! Sometimes it can! Other design factors may contribute to fatigue life. Parts subjected to very simple loading conditions. But, if the component is subjected to complex loads that complex loads that vary with time vary with time, a simple stress study can lead to incorrect results. In this case, a fatigue analysis is recommended. FATIGUE ANALYSIS nCode Design Life is an advanced tool for fatigue evaluation, developed by HBM. Fully integrated with ANSYS WorkBench 11.0 SP1. New version (for ANSYS 12.1) to be released this month. INTRODUCTION TO NCODE DESIGN LIFE PRODUCTS Different modules are available, with specific capabilities. INTRODUCTION TO NCODE DESIGN LIFE PRODUCTS Package/Module Description ANSYS nCode DesignLife Standard Base package including Stress-Life, Strain- Life and Dang Van analyzers ANSYS nCode DesignLife Modules/add-ons ANSYS nCode DesignLife Vibration Adds ability to do vibration fatigue analysis. Simulate swept sine and PSD loadings ANSYS nCode DesignLife Accelerated Testing Signal processing package complementary to vibration option. Design accelerated virtual and physical vibration tests. ANSYS nCode DesignLife Welds Fatigue life prediction for seam welds and spot welds. ANSYS nCode DesignLife Parallelization DesignLife is multi-threaded and licensed per core with one core included in the base package. What does nCode Design Life and ANSYS Fatigue tools have in common? They are both post post--processors processors, reading results from ANSYS. Some basic features basic features are available in both modules. nCode Design Life provides some additional advanced features, unavailable in ANSYS Fatigue Tools: Several signal treatment tools signal treatment tools, for load time histories; More material models material models (like Dang Van multiaxial method); More complex fatigue calculations complex fatigue calculations (like vibration analysis and accumulated damage evaluation); Easier to capture fatigue design intent design intent (with workflow templates and reference files); More detailed post post--processing processing (like hot-spot identification). NCODE DESIGN LIFE x ANSYS FATIGUE TOOLS nCode Design Life reads the stress results from the ANSYS simulation. Loading histories can be defined directly in Design Life. NCODE DESIGN LIFE BASIC PROCEDURE nCode Design Life main screen NCODE DESIGN LIFE BASIC PROCEDURE Desktop Reference Files (*.RST, loading curves...) Glyph Library A Glyph Glyph is a tool that represents a specific stage or operation from the fatigue calculation. For example, there are glyphs for geometry import, material definition, postprocessing Each glyph has input and output connections. Right-clicking a glyph provides advanced properties configuration. In Design Life, the user can define a fatigue calculation procedure by assembling some glyphs, creating a workflow creating a workflow. NCODE DESIGN LIFE BASIC PROCEDURE Some Glyph libraries available in nCode Design Life. NCODE DESIGN LIFE BASIC PROCEDURE Considering a typical SN fatigue calculation, the following glyphs are used: FE Input : FEA results import and load case combination SN Analysis : material definitions, loading conditions and fatigue solution advanced properties Hot Spot Detection : identification of critical points for damage plots FE Display : result plots Data Values Display : result tables NCODE DESIGN LIFE BASIC PROCEDURE Glyphs are connected, sharing and transferring information. This fatigue map can be saved can be saved as a Design Life workflow. NCODE DESIGN LIFE BASIC PROCEDURE Direct recognition Direct recognition of ANSYS results files (*.RST); Several cases can be combined in one single results file. Results from the FEA model can be visualized in the Design Life interface; FINITE ELEMENT INPUT nCode DesignLife automatically recognizes groups automatically recognizes groups, based on FEA file information. Parts, materials, element types User defined groups User defined groups can be created, with on-screen selection of nodes or elements. FINITE ELEMENT INPUT nCode DesignLife allows the definition of several fatigue material models, including: SN curves SN curves (standard, mean multi-curves, R-ratio multi-curves, Haigh multi-curves, Bastenaire and temperature multi-curves); N curves N curves (standard, mean multi-curves, R-ratio multi-curves and temperature multi-curves); Dang Van Dang Van multiaxial safety factor; Spot Weld Spot Weld analysis; Seam Weld Seam Weld analysis; MATERIAL MODELS nCode Design Life comes with a demo material database, with 100+ example materials, with different curves! Fatigue curves can be derived from mechanical properties derived from mechanical properties. For example, curve based on ultimate tensile stress of the material. The curves can also be manually specified manually specified. For example, a list of stress-cycle pairs to define a SN curve. MATERIAL MODELS Time Series Time history is obtained from transient analysis. Constant Amplitude Creates a 2 point stress history, by scaling and linear superposition. Time Step Combination of static loadcases to generate stress/strain history. Vibration Determines the rain flow to be used for further analysis. Duty Cycle Evaluates the combined effect of repeating loading events, with accumulated damage calculation. These loading conditions can be derived from FEA results, from static, transient, modal and harmonic analysis. LOADING CONDITIONS The fatigue solver provides some advanced setup options advanced setup options, such as: Result to be read Result to be read from FEA (stress, strain, displacement ); Method for combination Method for combination of stress/strain components (Absolute Max Principal, Signed von Mises, Signed Shear, Critical Plane); Mean stress correction Mean stress correction (Goodman, Gerber, Morrow, SWT); Elastic plastic correction Elastic plastic correction (Hoffmann-Seeger, Neuber); Duty cycle event processing event processing (independent, combined); Calculations on surface nodes only surface nodes only; Groups Groups to be processed; Unit system Unit system of the imported file; Check for static failure static failure; ADVANCED OPTIONS The fatigue solver provides results like damage, life, biaxiality ratio and dominant stress direction. Results are available in contour plots contour plots and data tables data tables. The hotspot glyph identifies the most critical regions most critical regions. POST-PROCESSING FEATURES Study of a steel lever, subjected to 4 loading classes. Each class is defined by two loads, shown on the next slide. SN Fatigue study is performed, with accumulated damage evaluation (via duty cycle). Frictionless supports are defined on the holes and hub base. DUTY CYCLE EXAMPLE DUTY CYCLE EXAMPLE Class Numb. of Cycles Tension Force (N) Remote Force (N) Max Min Max Min 1 10598 1500 200 700 -600 2 8673 600 400 950 -1200 3 4802 1700 500 450 -300 4 2610 200 50 100 -250 A B Tension Force, applied on the hole, in the X-direction Remote Force, aligned with holes axis, at Z = 30mm, in the Y-direction Two simulations are performed (max. and min. angles). Each simulation includes 4 loadsteps (one for each class). DUTY CYCLE EXAMPLE 2 RST files are created. They are renamed for easier reference, as MAX.RST and MIN.RST Design Life is available on the WorkBench launcher. A working directory is selected, where the RST files are. DUTY CYCLE EXAMPLE Workflow for the fatigue duty cycle calculation. DUTY CYCLE EXAMPLE Reads FEA results Combine files Material Properties Loading Definition Advanced Run Options Critical Regions Contour Plots Data Tables RST files are dragged to the FE Input glyph. Since a duty cycle analysis will be performed, those files are combined in a single one. Mesh and FEA results can be visualized in this glyph as well. DUTY CYCLE EXAMPLE A demo material will be used, with fatigue behavior derived from mechanical properties (UTS = 400 MPa). DUTY CYCLE EXAMPLE Loading history must be defined as a duty cycle. Each class is a duty cycle event (time step load provider). Number of cycles (repeats) is defined for each event. DUTY CYCLE EXAMPLE In each event, results can be selected from the global file, defining the loading conditions of this event. DUTY CYCLE EXAMPLE Class #1 is defined by the results from loadstep 1, from both simulations (MAX.RST and MIN.RST). Class Numb. of Cycles Tension Force (N) Remote Force (N) Max Min Max Min 1 10598 1500 200 700 -600 It is important to check if the run options are properly defined, in the Advanced Edit window. DUTY CYCLE EXAMPLE The solution is ready to run. Diagnostic messages can be obtained during the calculation for debug purposes. DUTY CYCLE EXAMPLE In the results post-processing, damage values can be studied. The hotspot feature identifies the 10 most critical nodes, showing their location over the geometry. DUTY CYCLE EXAMPLE Fully-integrated with ANSYS 12.1, available in May 2010 Main new features: Virtual Strain Gage Glyph for fatigue crack propagation Better integration with optimization tools like DesignXplorer and modeFrontier Named Selections recognition from WorkBench NEW FEATURES FOR NCODE 6.0 FOR MORE INFORMATION ABOUT NCODE DESIGN LIFE, CONTACT OUR TEAM THANK YOU