Intro To ANSYS NCode DL 14 5 L09 Stress Life Pt1

Introduction to ANSYS nCode DesignLife
Customer Training Material

Lecture 9: Stress-Life Fatigue Part I
L9-2
ANSYS, Inc. Proprietary
2013 ANSYS, Inc. All rights reserved.
Release 14.5
April 20133
Agenda
Discuss basics of Stress-Life (SN) method

Discuss S-N curves

Discuss mean stress effect
L9-3
Release 14.5
April 20133
Stress-Life Approach
Stress-life (SN) fatigue assumes that fatigue damage is produced by
fluctuating stresses
stresses drive fatigue
original numerical fatigue approach
based on alternating stress range and Whler fatigue curves (S-N curves)
vast amount of industry experience
still most widely used fatigue analysis method
only applicable to elastic stresses
limited to low stress/high cycle applications
usually more than 100,000 cycles to failure for ductile metals
simple technique
often can be checked with hand calculations
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In the mid-1800s, August Whler studied the relationship between
stress cycles and fatigue life using a rotating bending test that could
subject railway axels to alternating stresses
plotted the nominal stress to failure to develop original S-N curves

In 1901, O.H. Basquin proposed a log-log relationship for S-N curves
Beginnings of Stress-Life Fatigue
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April 20133
Basic SN Analysis Steps
Basis of stress-life (SN) fatigue is that the fatigue life is controlled by
stress reversals

Typical CAE SN analysis follows these basic steps
assemble a stress history using FE results and load provider
extract a combined uniaxial stress parameter
rainflow count the stress history to obtain range and mean for each cycle
calculate fatigue damage using uniaxial stress parameter and S-N curves
accumulate the damage
L9-6
Release 14.5
April 20133
S-N Curves
S-N curves are plots of elastic stress reversals versus cycles to failure
S (y-axis): either full stress amplitude range or alternating stress range (1/2
of the full range)
N (x-axis): total cycles to failure (initiation and propagation)
usually represented as log-log plots

S-N curves can be developed for
components
test and break actual components
materials
test and break machined material coupons
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April 20133
Component S-N Curves
Component S-N curves capture fatigue behavior of actual component
geometry and material are both captured
includes local features (notches, welds, etc.) that can be difficult to accurately
numerically model
captures component geometry, loading conditions, and material effects
application is limited to the particular component tested
original approach

To develop component S-N curves
test and break full components under
load controlled conditions
plot applied load versus number
cycles to failure
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April 20133
Material S-N Curves
Material S-N curves capture the fatigue behavior of a material
must be corrected to include specific component features
geometry, surface finish, surface treatment, size effect, etc.
not limited to particular component
most common approach
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April 20133
Material S-N Curves
To develop material S-N curves
test and break material coupons under load controlled conditions
smooth polished specimens used to minimize surface effects
computer controlled servo-hydraulic systems used to control loading and
monitor failure
typically use rotating bend test
test multiple specimens at each loading
fatigue results have wide data scatter
multiple tests are needed to obtain a statistical significant dataset
plot stress versus cycles to failure
fit a curve through the data
typically use mean curve
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April 20133
Material S-N Curves
Many engineering materials exhibit infinite life below some stress
level (endurance limit)
steel and titanium tend to have endurance limits
non-ferrous metals (aluminum, copper, etc.) tend not to have well-defined
endurance limits
endurance limit
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April 20133
For many engineering materials, S-N curves can be estimated from
the ultimate tensile stress using 3 straight lines
S-N Curves
Ferrous Alloys
cycles stress
10
6
0.357*S
u
10
3

0.90*S
u

Titanium Alloys
cycles stress
10
6
0.307*S
u
10
3

0.80*S
u

Aluminum Alloys
cycles stress
5*10
8
0.258*S
u
10
3

0.70*S
u

region below 1e3 cycles, is
often ignored, because SN is
not applicable to low-cycle
fatigue
L9-12
Release 14.5
April 20133
Material S-N Curves
Design life for most ferrous metals is between 1e3 and 1e6 cycles
S = alternating stress
A = material coefficient
b = material exponent
N = number of cycles
( )
b
S N * A =
b = Basquins slope
( )
1 2
2 1
N log - N log
S log - S log
b
=
Typical b values
welded components: b = -0.33
electronic components: b = -0.25
high cycle components without stress concentrations: b = -0.1
L9-13
Release 14.5
April 20133
S-N Curves
For ANSYS nCode DesignLife, material S-N curves are defined in
Engineering Data
L9-14
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April 20133
Predefined SN Process
SN DesignLife systems are created by dropping one of the predefined
systems onto the Project Schematic
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April 20133
SN Properties
DesignLife specifies most commonly modified SN parameters on the
Properties menu
StressLife_Analysis engine > RMB > Properties
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AnalysisGroup
AnalysisGroup on Properties Menu sets how FE results will be
handled within DesignLife
user action is typically not required for Analysis Groups
Note: within DesignLife an analysis group is a group of FE entities (nodes,
elements, etc.) for which FE results will be translated

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AnalysisGroup
Some AnalysisGroup Options
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SNEngine
SNEngine controls the stress-life solver
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SNEngine
Some SNEngine options
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SN Properties
Other SN properties are accessed using Advanced Edit
StressLife_Analysis > RMB > Advanced Edit
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April 20133
Mean Stress Effect
Alternating peak stress range is the primary influence on fatigue life

Mean stress that occurs during the loading is a secondary effect
tensile mean stresses reduce fatigue life
compressive mean stresses increase fatigue life
commonly ignored
S
max
= maximum stress
S
min
= minimum stress
S
m
= mean stress
R = stress ratio (S
min
/S
max
)
R = - 1
R = 0
no mean stress tensile mean stress
L9-22
Release 14.5
April 20133
Mean Stress Effect Methods
Mean stress effect is included by
using distinct S-N curves for each mean stress level
fatigue tests are conducted at multiple mean stress levels either based on
actual mean stress value or R-ratio
if mean stress lies between curves, values are interpolated
adjusting alternating stress range using a mean stress correction theory
Goodman and Gerber are most widely used for SN fatigue
L9-23
Release 14.5
April 20133
Mean Stress Effect By Interpolation
Mean stress effect can be included by using distinct S-N curves for
each mean stress level and interpolating between them
R = -1: no mean stress
increasing tensile mean
stress decreases fatigue life
L9-24
Release 14.5
April 20133
Specify Mean Stress Effect
Mean Stress Correction method is specified using Properties menu
StressLife_Analysis> RMB > Properties SNEngine_MeanStressCorrection

Note: for Goodman or Gerber to be used, S-N data must contain a
curve with no mean stress (R = -1)
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Correction theories can be used to include mean stress effect
empirical rules developed from test results
Goodman and Gerber are most widely used

Goodman and Gerber theories are based on the assumption that the
alternating stress range and the tensile mean stress are either linearly
(Goodman) or parabolically related (Gerber)
Mean Stress Theories
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Haigh diagram represents combinations of cyclic stress and mean
stress that cause failure
plot of stress amplitude versus mean stress
all points on the curves produces equivalent damage
safe designs fall below the curve
unsafe designs fall above the curve
test data tends to fall between Goodman and Gerber theories
Goodman is more conservative
Gerber tends to be more accurate
Gerber parabola
Goodman line
safe life
when S
m
= 0: failure occurs
when stress range equals
the endurance limit
when S
m
= S
u
: tensile failure with
single application of loading (no
alternating stress)
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Release 14.5
April 20133
Mean stress theories adjust the calculated stress range by the ratio of
the mean stress to the ultimate tensile stress
Gerber parabola:
ef
S
Su
Sm
Sa
|
|
.
|
\
|
|
.
|
\
|
=
2
1
Goodman line:
ef
S
Su
Sm
Sa
|
.
|
\
|
= 1
S
a
= stress amplitude (stress range)
S
ef
= effective stress amplitude (adjusted for mean stress effect)
S
m
= mean stress
S
u
= ultimate tensile stress
L9-28
Release 14.5
April 20133
Summary
SN method relates stress cycles to fatigue life using S-N curves
simple to implement
accurate for high cycle applications
large amount of existing SN data and experience

Component S-N curves apply to specific components
directly accounts for geometry, manufacturing, surface finish, etc.

Material S-N curves apply to a material
can be modified to account for surface treatment, surface finish, etc.

Effect of mean stress can be included
interpolation between multiple S-N curves
Goodman or Gerber mean stress correction theory
L9-29
Release 14.5
April 20133
Workshop 7
Workshop 7: Constant Amplitude SN Analysis
restore archive
solve Mechanical model
link nCode SN Constant Amplitude system to Mechanical model
open DesignLife
modify load mapping
solve
review multi-axial assessment
modify mean stress correction
solve
post-process

Intro To ANSYS NCode DL 14 5 L09 Stress Life Pt1

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