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Fatigue based on crack formation. Fatigue based on crack growth. When in the design phase, or for components requiring only a few cycles of life, crack formation may be sufficient. For highly engineered parts, for components that are manufactured in bulk such as automotive parts, or for in-service life prediction, crack growth may be required.
Crack Formation Crack Growth
Cracks/flaws are not explicitly considered. Use ANSYS to predict far-field (un-cracked body) conditions. ANSYS results are fed to a fatigue analysis tool.
Basic approach could be a S-N table look-up, performed by hand or via macros. More comprehensive fatigue analysis using nCode.
Crack is not included in ANSYS analysis, but stress field in crack region is fed to separate fatigue crack propagation tool, such as nCode. Crack is included in ANSYS model.
Need to continually update mesh to account for crack growth. May or may not know crack path. Various methods used to obtain K, which is then used with a crack growth law to determine remaining life. Additional energy approaches include virtual crack closure technique (VCCT) and cohesive zone modeling, typically used in delamination prediction.
Complex loading:
Perform a comprehensive fatigue analysis using nCode.
Goodman Diagram
To include the effect of mean stress, approaches have been developed to take the mean stress into account.
The alternating stress is plotted against the mean stress. The straight line representation is called the Goodman diagram.
The Goodman diagram is typically preferred in engineering design. Actual data can vary around lines by being either concave or convex.
Points below Goodman line are considered safe, points above line are considered failed.
m a = e 1 u
Goodman Diagram
Finite element analysis of stent inserted in artery, minimum and maximum cyclic loading due to blood pressure. Mean and alternating stress at every point in the model is found and plotted in ANSYS using APDL to create Goodman diagram.
Goodman Diagram
Goodman line
ANSYS now offers an advanced set of fatigue analysis capabilities built on nCodes DesignLife technology.
Integrated with the ANSYS Workbench platform. Can run stand-alone using ANSYS RST, DYNA D3PLOT, ABAQUS, NASTRAN, etc. Provides ease of use and powerful fatigue analysis.
nCode DesignLife
nCode is the leading developer of fatigue analysis software in the world. DesignLife is the easiest-to-use, most powerful, and most flexible CAE/FEA fatigue and durability software in the industry. nCode provides their DesignLife Material Library for distribution to all customers.
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Low cycle and high cycle fatigue analysis. General loading capability uses rainflow cycle counting to define fatigue cycles. Damage accumulation based on Miners rule to account for different amplitude loading. Plasticity corrections. Mean stress corrections. Time-history corrections. Multiaxial fatigue.
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Fatigue Curves
Stress-life curve:
Makes no attempt at modeling plasticity. Appropriate for high cycle fatigue. Models material yielding and plasticity. Appropriate for low cycle fatigue.
Strain-life curve:
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Fatigue Loading
Material fatigue curves are created with constant amplitude sinusoidal loading.
Typically with a zero mean stress, i.e. fully-reversed loading. Real loading can be constant amplitude, blocks of different amplitudes, or variable amplitude, and can have non-zero mean stress.
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To account for variable amplitude loading in fatigue calculations, must have a method to define fatigue cycles in a varying waveform.
Drain water starting at lowest valley, measure total & mean depth drained
Range 450 50
Continue by draining next lowest, etc.
No. 1 1 2
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To include the effect of multiple blocks of different amplitude cyclic loading, Miners rule of damage accumulation is used.
Calculates partial damage for each amplitude loading. Failure is predicted when the sum of all partial damage equals one.
Partial damage =
ni Ni
n n1 n + 2 + 3 + = 1 N f1 N f 2 N f 3
Miners rule is very simplistic (for example, the order of loading has no effect), but it is widely used.
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Elastic-Plastic Corrections
For low-cycle fatigue analyses, where plasticity plays a role, two approaches are available:
Calculate the nonlinear material response and use in fatigue calculations. Use linear material response with a correction to account for material yielding, typically used for localized regions of yielding in notches.
Assumes elastic strain energy = plastic strain energy. Can therefore calculate plastic response directly from elastic solution.
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Fatigue damage is influenced by the mean stress of each cycle. Mean stress correction methods allow the effect of mean stress to be modeled and taken into account. Supported methods:
Goodman Gerber Interpolate FKM Goodman Tension Only Gerber Tension Only
u e (R ) = a (1 + R ) + u m a (1 R )
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Time-history compression.
Time series analysis can be accelerated with various methods. Peak-valley method uses only the load reversals. Limits method uses only the max and min of each load channel.
Condense stress tensor down to a single stress, such as a signed Von Mises or absolute maximum principal value. Critical plane approach finds plane with the most damage.
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nCode Architecture
Each glyph represents an engineering function that can be used to graphically create an analysis process. Double-click the glyph header bar (or right-click) to access properties. Common processes are available for use, can create custom processes. Can save the process as a .flo file.
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Define type of fatigue analysis and settings. Also, perform load and material mapping.
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Must define which cyclic loading to associate with which FE load, and which fatigue material properties go with which component.
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Constant amplitude.
Apply loading in FE analysis. Loading is scaled assuming sine wave.
Time series.
Apply loading in FE analysis. Define load time history factors to scale FE loading.
Duty cycle.
Combination of various loadings.
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nCode Demonstration
Demonstration problem:
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