ANSYS nCode DesignLife

for
13.0 ANSYS Workbench

Jeff Mentley
HBM-nCode
1

2011 ANSYS, Inc.

September 8, 2011

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

2011 ANSYS, Inc.

September 8, 2011

ANSYS nCode DesignLife

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

2011 ANSYS, Inc.

September 8, 2011

What is Fatigue?

The initiation and growth of a

crack, or growth of a pre-existing
defect, until it reaches a critical
size.
The progressive and localized
structural damage that occurs
when a material is subjected to
cyclic loading.
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Strain

Stress

Failure under a repeated or

otherwise varying load which never
reaches a level sufficient to cause
failure in a single application.

Stress

Fatigue is:

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 killed
Early wheel design caused vibrations
New wheel design
Based upon streetcar design
Not tested at high speed before service
Complete prototypes never tested
Crash findings
Caused by crack in wheel
Dynamic, repetitive forces had not
been accounted for in design
Design lacked an adequate margin of
safety

2011 ANSYS, Inc.

September 8, 2011

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

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.
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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

2011 ANSYS, Inc.

September 8, 2011

Fatigue Analysis: Stress-Life (SN)

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

Whler circa 1850

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.
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September 8, 2011

Stress, centners/zoll2

Used extensively for welded joints

and non-metallics

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
Cycle counting and plasticity
corrections difficult to do by
hand.

Plastic (Low Cycle

Fatigue Line)

Elastic (High Cycle

Fatigue Line)

N
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2011 ANSYS, Inc.

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Fatigue Analysis: Crack Growth

Crack growth known as crack
propagation, or fracture mechanics
Crack

Predicts cycle by cycle crack growth

Used in aerospace Damage Tolerance

analysis

Determine impact of known or

suspected flaws

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2011 ANSYS, Inc.

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ANSYS nCode DesignLife

ANSYS
Workbench

Engineering
Data
Materials

Loads

Stresses

Mechanical

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September 8, 2011

DesignLife

ANSYS nCode DesignLife

nCode OEM Partnership
nCode DesignLife
Advanced Fatigue
Analysis
Process Orientation
Ease of Use
Workbench Integration
DesignLife Systems
Design Parameters
Material library

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2011 ANSYS, Inc.

September 8, 2011

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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2011 ANSYS, Inc.

September 8, 2011

ANSYS nCode DesignLife - Features

Intuitive and easy to use software for
performing fatigue analysis of finite
element models.
Efficiently analyze large finite element
models and complete usage schedules.
Wide range of fatigue analysis capabilities
including stress-life, strain-life, multi-axial,
weld analysis, virtual shaker table, and
more.
Single environment for both Test and CAE
data.
Extensive material database

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2011 ANSYS, Inc.

September 8, 2011

ANSYS nCode DesignLife - Capabilities

ANSYS nCode DesignLife has an extensive scope of fatigue capabilities

Strain-Life (automated multi-axial corrections)

Stress-Life (single, multi-curve, Haigh diagrams)
Crack Growth (LEFM)
Seam welds and spot welds
High temperature fatigue
Vibration fatigue (shaker simulation)
Virtual Strain gage
Complete duty cycles / flight spectrums
Multiple runs in a single analysis
Multi-processor enabled for fast results

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Finite Element results supported

Static (linear superposition)
Transient
Modal
Frequency Response
Linear & Non-linear
Finite Element solvers supported
ANSYS
Abaqus
Nastran
LS-Dyna

ANSYS nCode DesignLife - Benefits

Perform virtual durability assessment up front to reduce reliance on
physical test and avoid costly design and tooling changes
Perform smarter and quicker physical tests by simulating first
Design durability into your products and reduce warranty claims

Standardize analysis processes to improve consistency and quality

Automate processes to better utilize engineers time and workload
Assess more design options, consider more realistic loading conditions
and more confidently reduce cost and weight

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2011 ANSYS, Inc.

September 8, 2011

ANSYS 13 nCode DesignLife SP1

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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

2011 ANSYS, Inc.

September 8, 2011

ANSYS nCode DesignLife

Questions

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2011 ANSYS, Inc.

September 8, 2011

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

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2011 ANSYS, Inc.

September 8, 2011

THANK YOU!