FEMFAT 5.

2 - MAX
User manual

CONTENTS
1 The FEMFAT max Module ___________________________ 4
1.1 Program procedure of FEMFAT max ____________________ 5
1.2 Femfat.ini file editor ____________________________________ 9
1.3 Defining the project ___________________________________ 9

2 Working with FEMFAT max __________________________ 10

2.1 FEM model data _____________________________________ 11
2.2 Groups_____________________________________________ 11
2.2.1 The DETAILED RESULTS group _____________________ 11
2.3 Load time-data input with ChannelMAX and TransMAX __ 13
2.3.1 ChannelMAX channels ___________________________ 13
2.3.1.1 Creating a new channel / Deleting a channel ____________ 14
2.3.1.2 Channel definition table _____________________________ 15
2.3.1.3 Importing the MAX input file _________________________ 27
2.3.1.4 Writing to the MAX input file _________________________ 29
2.3.1.5 Importing the load histories __________________________ 29
2.3.1.6 The signal generator in ChannelMAX __________________ 29
2.3.1.7 Compressing load histories __________________________ 31
2.3.1.8 Working with modal stresses in ChannelMAX _________ 34
2.3.2 TransMAX time steps __________________________ 36
2.3.2.1 Definition of transient load cases _____________________ 36
2.3.2.2 Definition of the constant load case ___________________ 46
2.3.2.3 Analysis preferences _______________________________ 46
2.3.2.4 Importing the TransMAX input file ____________________ 48
2.3.2.5 Writing to the MAXT input file ________________________ 48
2.4 Material data ________________________________________ 51
2.4.1 Material parameters required for FEMFAT max ________ 51
2.5 Node characteristics _________________________________ 53
2.5.1 Process influence _________________________________ 53
2.6 Influence factors_____________________________________ 54
2.6.1 General factors ___________________________________ 54
2.6.1.1 Stress gradient influence factor ______________________ 55
2.6.1.2 Mean stress influence factor _________________________ 55
2.6.1.3 Constant stresses __________________________________ 56
2.6.1.4 FEMFAT plast (Stress Rearrangement) _______________ 57
2.6.1.5 Influence of rotating principal stress __________________ 57
2.6.1.6 Boundary layer ____________________________________ 57
2.6.1.7 Influence of fiber orientation _________________________ 57

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2.6.2 WELD / SPOT / LAMINATES _____________________ 60

2.6.2.1 WELD ____________________________________________ 60
2.6.2.2 LAMINATES ______________________________________ 62
2.7 Strain gage information - STRAIN COMP_________________ 65
2.7.1 Signal length _____________________________________ 65
2.8 Analysis parameters _________________________________ 66
2.8.1 Analysis target ____________________________________ 66
2.8.1.1 Damage___________________________________________ 67
2.8.1.2 Endurance Safety Factor ____________________________ 67
2.8.1.3 Static Safety Factor _________________________________ 67
2.8.1.4 Stress/Strain Comparison ___________________________ 67
2.8.1.5 Degree of multiaxiality ______________________________ 67
2.8.2 Global parameters _________________________________ 69
2.8.2.1 Stress selection ____________________________________ 69
2.8.2.2 Survival probability _________________________________ 75
2.8.2.3 Rainflow classification ______________________________ 75
2.8.3 Analysis filter _____________________________________ 77
2.8.3.1 Relative stress limit_________________________________ 78
2.8.3.2 Absolute stress limit ________________________________ 79
2.8.3.3 Analysis filter for WELD nodes _______________________ 80
2.8.3.4 Analysis filter for SPOT nodes _______________________ 80
2.8.4 Cutting Plane Parameters ___________________________ 80
2.8.4.1 Cutting plane/node filter _____________________________ 81
2.8.4.2 Angle between cutting planes ________________________ 81
2.8.4.3 Filtering method ___________________________________ 82
2.8.4.4 Channel stress filter limit method 1 ___________________ 84
2.8.4.5 Upper stress filter limit Method 1 _____________________ 84
2.8.4.6 Lower filter limit Method 2 ___________________________ 86
2.8.4.7 Upper filter limit Method 2 ___________________________ 86
2.8.5 Result group _____________________________________ 88
2.8.6 Result visualization ________________________________ 88
2.9 Scratch settings _____________________________________ 89
2.9.1 ChannelMAX ___________________________________ 89
2.9.1.1 Creating the ChannelMAX scratch files _______________ 90
2.9.2 TransMAX _____________________________________ 92
2.9.2.1 Creating the scratch files for TransMAX________________ 92
2.9.2.2 Stress file settings _________________________________ 93
2.9.2.3 Creating New Scratch Files __________________________ 93
2.9.2.4 Using existing scratch files __________________________ 93
2.9.3 Checking MAX input data___________________________ 94
2.10 Output _____________________________________________ 94
2.10.1 FPS Setting ______________________________________ 94

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2.10.2 DMA-Column Setting_______________________________ 94

2.10.3 Result modification ________________________________ 95
2.10.4 Module-specific outputs_____________________________ 95
2.10.4.1 MAX _____________________________________________ 95
2.10.4.2 SPOT ____________________________________________ 98
2.10.4.3 STRAIN __________________________________________ 98
2.11 Report _____________________________________________ 99
2.11.1 Result output for fiber reinforced plastics _______________ 99
2.11.2 Relative stress limit ________________________________ 99
2.12 Analyze ___________________________________________ 100
2.13 Visualization _______________________________________ 100
2.13.1 Analysis Visualization _____________________________ 100
2.13.2 MAX visualization ________________________________ 100
2.13.2.1 History __________________________________________ 100
2.13.2.2 Strain Gage Chart _________________________________ 102
2.13.2.3 FEMFAT Visualizer ________________________________ 102

2.14 FEMFAT menus____________________________________ 103

2.15 Result Manager_____________________________________ 103
2.16 Postprocessing ____________________________________ 103

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1 The FEMFAT max Module

The determination of operational strength under static and/or dynamic loads at
an early stage of component development is playing an increasingly important
role in many branches of vehicle and mechanical engineering. FEMFAT is a
software package that can perform operational strength analyses on the basis of
finite element analysis results.
"Testing" and "numerical simulation" provide two principle methods for
component strength optimization. Increasingly, numerical models are applied
in order to acquire statistically backed damage forecasts for dynamically
loaded components in the early stages of development.
The primary aims here are:
• Complete integration in the CAE process
• Acquisition of operational strength data at an early stage of component
development, restriction of time- and cost-intensive component testing to a
minimum
• The possibility of eliminating weak links in the design by early recognition
at the component draft stage
• Comparatively low development costs compared to complex operational
strength tests
The FEMFAT max module was developed for operational strength analysis
of structures with MultiAXial loading. It helps development engineers to find
the optimum component design with regard to extremely complex dynamic
loading. In this context, this means a loading history that cannot be subdivided
into one mean stress, one constant stress and one amplitude stress.

Fig. 1 – Data flow from and to FEMFAT max

All load history information is summarized by means of the critical cutting

plane hypothesis, specially developed for multi-axial operational strength
analysis. This method was derived from the methods introduced in FEMFAT

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basic for the mean stress influence in a multi-axial combination of stress

amplitude and mean stress tensor.
The results are damage values or safety factors for all relevant cutting planes.
This can be automatically selected by applying a filter, whereby the largest
damage value or the smallest safety factor of all cutting planes is issued at the
node.
By using FEMFAT plast, mean stress redistributions can be considered if
the material yield stress is locally exceeded. The residual stress conditions
generated by these plastic deformations can then be considered in the
operational strength analysis.

1.1 Program procedure of FEMFAT max

The procedure described here is recommended for operational strength
analyses using FEMFAT max because of its proven track record.
In order to perform MAX analyses it is necessary to provide the program with,
or make available, the following data:

• Geometrical model data (nodes, elements)

The geometrical data are required in order to subsequently calculate stress

gradients (i.e. the maximum stress difference) between neighboring nodes.
This stress gradient and the relative stress gradient derived from it form the
basis for consideration of the notch effect (and the associated supporting
effect), which can have a critical influence on the S/N curve under
consideration.
Solid and shell elements can be processed with the current program
version. Stress data at beam and rod elements will not be processed.

• Group data

Groups can consist of nodes and/or elements and serve to simplify definition
of certain regions of the entity, for which specific parameters are to be
specified.
In FEMFAT, groups are used to assign material data, surface roughness
data, tempering conditions, etc. to certain nodes. Identification of nodes via
node numbers is not necessary if further parameters are known.
All operations apply to the current group only, which must contain the
nodes and elements of the regions of interest. It is therefore best to
previously define the appropriate groups in the preprocessor application or in
FEMFAT visualizer. This group data can be imported into FEMFAT
for further processing.
FEMFAT also provides a number of functions for generating and editing
groups.

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Because damage analyses are only performed on the nodes and elements
contained in the current group, you have the option of carrying out detailed
investigations of certain regions.
In the case of a 3D element model, the standard approach is to perform the
analysis only on the surface which is determined automatically by the
application. In this case, however, the group being analyzed not only
consists of the surface nodes but also of the nodes directly below the
surface, so that the relative stress gradient for the surface nodes can be
calculated.

• Stress data

The stress conditions at each node of the current analysis group are an
important basic element of operational strength analyses.
According to how forces acting on the component vary with time,
FEMFAT offers two differing MAX options (ChannelMAX and
TransMAX):
o ChannelMAX
ChannelMAX is useful if the load can be reduced to time-dependent,
but otherwise fixed, loads, whereby no non-linear effects may occur.
Various channels are considered in the analysis. Each of these channels is
defined by a finite element stress result and by a load history. The stress
tensor at a node corresponds to a specific load case; an example of this
are vertical forces on vehicle structures. The load histories define the
stress tensor history.
If no other limitations are imposed by hard or software, FEMFAT
max works with any number of different dynamic channels per analysis.
This can be modified in the initialization file (femfat.ini) (see FEMFAT
basic user manual Chapter 1.1 - Femfat.ini File Editor).
o TransMAX
Analysis using TransMAX should always be performed when no fixed
loads act on the component and/or non-linear effects need to be
considered (e.g. bush bearings), i.e. for transient loads.
However, using TransMAX, a finite element analysis must be
performed for every single point in time, which can lead to substantial
"preparation effort" for operational strength analyses.
The nodal stress data must be exported to the program in stress record
format. It is assumed that the stress data are available node-referenced for
each element and are defined in a global Cartesian coordinate system.

• Material data

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A number of material data must be defined for operational strength analyses

in order to correctly document the dynamic strength behavior of the
material.
The easiest way is to import the material data from the material database
in the form of a material data file (*.ffd). This file contains the general
fatigue strength data for tensile, compressive, bending and shear stress
(record 218) and the tensile/compressive S/N curve of the smooth, un-
notched specimen (record 223). In addition, further parameters, such as for
gradient and technological parameter influences, can also be saved.
If no appropriate material data file is available, all material data necessary
for the analysis may also be entered interactively, if known.
If only incomplete data are available (but at least material class and tensile
strength values), the remaining data necessary for analyses can be
approximately determined in FEMFAT with the assistance of the material
generator.

• Assigning characteristics at nodes

Analysis of damage values or the endurance limit safety factor is always

performed at model nodes. In order to have the relevant influence
parameters considered they must be specified beforehand for the individual
nodes.
Material definition is absolutely necessary; all further quantities (surface
roughness, surface treatment, tempering condition for tempered steels, etc.)
need only be given if the corresponding influences are to be considered.
• Selecting the desired analysis method

Selecting the desired analysis procedure FEMFAT provides a number of

procedures for calculating influence parameters. These procedures can be
selected by the user.
If no particular procedure is selected, analyses are performed using the
default procedures.

• Activation/deactivation of influence parameters

In order to easily investigate the effects of certain influence parameters on

the operational strength analysis, each influence can be activated and
deactivated individually.

• Specifying the desired output quantities

o The result data from the FEMFAT operational strength analysis are
written as node-referenced data to the output file (mostly with *.dma
suffix). This file can then be imported into a FEM postprocessor
application and the result data graphically displayed on the FEM model.

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Damage values, endurance limit safety factors, equivalent stresses, local

S/N data, influence factors, relative stress gradients and others can be
visualized in the FEM postprocessor program. As an alternative, the
VISUALIZER can also be used directly in FEMFAT for analysis
visualization.
o All detailed results can be saved in the FEMFAT report file (*.pro)
together with all influence parameters for the local component S/N
curves of the calculated nodes, the influence of stress redistributions, etc.,
and can thus be easily followed during detailed investigations.
The user can select which data is to be written to the report file. If these
possibilities are generously utilized, very large amounts of data may
result.
For this reason, FEMFAT provides the option of applying a stress
referenced output filter in order to restrict output to the high-load
regions of a model. Here, a stress limit is specified in order to suppress
output of nodes with low stresses.

• Operational strength analyses at the nodes of the current group

During operational strength analysis, endurance limit safety factor or damage

value analysis is performed by default only at the surface nodes of the
current group.
A substantially more calculation intensive version can also be selected, i.e.
analysis at all nodes (including internal) based on 3D stress conditions (see
also Chapter 2.8.4.1 Cutting plane/node filter)
However, there is also the possibility of using the stress-referenced
analysis filter to have the analysis restricted to only the high-load regions
of the model instead of at all nodes in the current group.
• Parallel FEMFAT analysis
With FEMFAT max it is possible to automatically divide the analysis
into several parallel jobs and run them on the current computer.
Parallelization is performed by automatically splitting the analysis group
into a given number of equally sized sub-groups and starting the respective
number of FEMFAT jobs each with a sub-group. The sub-results are
subsequently amalgamated automatically to form an overall result.

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A separate feature, FEMFAT parallel, is utilized for licensing the

parallel damage life analysis. When the analysis begins, and depending on
the corresponding influence factors and analysis method, a certain number of
tokens corresponding to this feature are checked out for each additional
FEMFAT job and are then checked back in once the analysis is complete. A
refreshable display indicates the - based on the remaining available licenses -
possible number of parallel jobs. For the batch mode: If not enough licenses
are available for the number of parallel analyses specified in the job file, the
currently maximum possible number of parallel jobs is used for
parallelization.

1.2 Femfat.ini file editor

See BASIC manual.

1.3 Defining the project

See BASIC manual.

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2 Working with FEMFAT max

FEMFAT can be launched under Linux/UNIX using the
installation_path/bin/femfat command and under MS Windows by double-
clicking the FEMFAT icon or by selecting the appropriate item in the Start
menu.

Figure 2– FEMFAT max opening screen

When FEMFAT is first started, only the main modules are displayed on the
left of the screen. The input data structure of the module can be displayed by
clicking on ChannelMAX or TransMAX.
The input required for FEMFAT max is grouped thematically in the various
menu items.
In order to avoid input errors it is recommended to work through the menu
items consecutively.

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2.1 FEM model data

See BASIC manual or Interface manual.

2.2 Groups
See the BASIC manual or the Interface manual for a general description.

By default, FEMFAT max assumes that all damage originates on the

surface. If the current group contains no surface nodes, no MAX analysis is
carried out. This is only possible with the option 3D stresses, all nodes in
the MAX analysis parameters menu (see Chapter 2.8.4.1 Cutting plane/node
filter) !!!

2.2.1 The DETAILED RESULTS group

Figure 3 - Group menu - History & Detailed Results

The following additional, detailed information is exported to ASCII files (CSV

files) and the fps file for the nodes of this group:
• maximum stress values for each channel (ChannelMAX only)
• unit stress values for each channel (ChannelMAX only)
• Equivalent stress history

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• Partial damage history

• Total damage history
• S/N curve
• Haigh diagram

This group can be both:

• the analysis group itself, i.e. the data of all nodes in this group are
output in an ASCII file,
or
• a reference group, i.e. for all those nodes that are contained both in the
analysis group and in the corresponding special group, certain data is
output to files or can be visualized in FEMFAT.
The ASCII files with the detailed results contain the following information:
Basic material Signed equivalent stress or equivalent stress history in the
nodes critical cutting plane
WELD nodes Selected WELD equivalent stresses or their histories (see
FEMFAT weld user manual Chapter 4.1.11 - WELD
equivalent stresses)
SPOT nodes Signed Mises stress or the history of the user-defined
equivalent stress.
An explicit analysis is (corresponding to the usual SPOT
concept) carried out only for nodes of the outer roundel.
Nodes of the inner roundel are assigned the equivalent
stresses of the associated outer roundel nodes. Central
nodes contain the equivalent stress of the most critical node
of the particular roundel.

Additionally, the equivalent stress and damage histories are then also available
for visualization in VISUALIZER.

The file names are specified in the Output menu.

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2.3 Load time-data

time input with ChannelMAX and
TransMAX
With multi--axial operational strength analyses,
yses, very large amounts of
information are required.
In ChannelMAX and TransMAX, two options for solving multi-axial
multi
problems are available to the user:

2.3.1 ChannelMAX channels

Figure 4 - ChannelMAX channel definition

If the component is stressed by a finite number of fixed loads and load

histories, and no non-linear
non linear effects occur, an operational strength analysis with
ChannelMAX is advisable.
As previously mentioned, every load, together with its history, is known as a
channel in ChannelMAX.
In contrast with the FEMFAT basic analysis concept, the division into
amplitude and mean stress is not clear
clear-cut.
cut. Every channel can have its own
history.

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ChannelMAX needs this channel information as input. Input is in three

stages:
1. Channel definition in a table, containing both the names as well as the
formats of the FEM stress result files and the history files. The
channel definition can be saved in a MAX input file.
2. In the next step, the channel history files will be imported into the
application in accordance with the channel definition (see chapter
2.3.1.5
2.3.1.5).
3. In order to complete load information input, the element-related
element stress
tensors must
must still be imported/scratched (see chapter 2.9.1).
Points 2 and 3 are automatically performed when analysis commences if
manual processing was not carried out.

2.3.1.1 Creating
reating a new channel / Deleting a channel
This option should be used if no adequate MAX input file is available or if a
new channel is to be defined and added.
Input and modification of channels is now carried out with the aid of a table.
In order to create
create the channels, the number of channels must be directly entered
in the input box or adjusted using the arrows.

Figure 5 - Creating and deleting channels

A control menu appears by right-clicking

right clicking on the table. It is also possible to
select and delete several channels simultaneously using the Shift or Ctrl key
(see Figure 6).
). If a great number of channels are being handled, the desired
channel can also be reached by direct input of the channel number in the input
box of the current channel.

Figure 6 - Popup window in table for deleting channels

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In order to assign the corresponding data to this channel, left-click on the

corresponding entry field and enter the value.
The maximum number of channels in ChannelMAX is preset to 100 in the
initialization file (femfat.ini). If a larger number of channels is required, the
FEMFAT femfat.ini file must be opened and modified accordingly.

When importing the stress data, the program creates a scratch file for each
channel (see Chapter 2.3.1.2.4 Scratch). It is very important that each channel
has its own scratch file with a unique name. Make sure that never more than one
channel can access the same scratch file.
Due to the operating system, there are limitations as to the maximum number
of files which may be open at the same time. If problems with the maximum
number of channels arise in ChannelMAX as a result of this limitation,
these can be solved by modification of the respective system parameters.

2.3.1.2 Channel definition table

The column width can be altered using the mouse. Right-clicking on the
column header sets the column to the optimum width. Double-clicking with the
left mouse button on the column header resets the width of the table to the
default setting.
Clicking on a table cell allows data entry using either a Combo box, open-file
dialog box or input box (see Figure 7). Horizontal navigation is by means of
the Tab or Shift+Tab keys; the up/down arrows are used to move
vertically in the table.

Figure 7 - Data entry in the table

To simplify table input, an anchor channel can be defined. If a table row is now
altered, these alterations are adopted for all other rows up to the anchor row.
The anchor channel can be entered directly using the channel number, or be
selected with the right mouse button. The anchor channel is highlighted in
green in the table (see Figure 8). Using the check box the final channel

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is adopted as the anchor channel, even if a channel is subsequently added or

deleted.

Figure 8 - Anchor channel in the channel definition table

Two options are available for editing several channels simultaneously, with
and without use of an anchor channel:
1. Using an anchor channel: Editing of a cell above the anchor channel is
adopted for all the cells below this, as far as the anchor channel. The
cell auto-fill as far as the anchor channel follows similar rules to those
in common spreadsheet programs. If the current channel is in the first
row, the entries are simply copied to the anchor channel, with the
exception of those columns that do not allow the same entries in
different channels (e.g. channel label or scratch file name). It is also
possible to repeat the contents of several separately selected channels as
far as the anchor. This is done with the aid of the menu in the pop-up
window (click on the current cell with the right mouse, see Figure 9). If
the current cell is located below the anchor channel, the alteration only
concerns the current channel.

Figure 9 - Repetition of 3 channels as far as anchor

2. Without an anchor channel: With the aid of the pop-up window normal
copies or incremental copies can be made. The normal copy is only
possible in those columns that allow the same entries in different
channels. The copies are only adopted for marked channels located
below the current channel. Marked channels above the current channel
remain unaltered.

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Figure 10 - Copying selected channels

2.3.1.2.1 Stress data record

One stress record is defined per channel. First, the format must be specified.
For further information about the formats supported by FEMFAT please read
the Interfaces manual.
After selecting the file format, the path and name of the stress file must be
entered in the input box.
A stress file can contain more than one load case, although each channel may
only be assigned one of these (see Chapter 2.3.1.2.2 Load case).
Additional settings can be configured for some formats ("stress-format
specific options"):
1. Data allocation at element node or averaged at nodes: this option is
available for Nastran op2, Abaqus fil, Permas post and Altair h3d.
2. Reading node forces for WELD SSZ and SPOT CHexa: If this
checkbox is enabled, additional node forces for force-based weld
assessments and spot weld assessments can be read when using the
Nastran op2 and Medina formats. Since this option may require a lot of
memory, it should only be enabled if necessary.
3. Abaqus odb: Ignore inconsistent transformation data for a model
change: The default setting is for the stress data to always be
transformed into the global coordinate system using the associated
transformation matrices of the respective channel. Transformation into
the global coordinate system is necessary so that during stress
averaging at the node all stresses are located in the same coordinate
system. In special cases, however, such as for a channel-based
assessment of components with a great degree of deformation (e.g.
elastomers), the coordinate system must be body fixed so that the stress
analysis in cutting planes delivers correct histories. This can be
achieved by disabling the button. In this case, transformation of the
stress data for all channels into the global coordinate system is always
performed using the transformation matrices of the first load case of the
odb file defined for the first channel. When a model change has been
performed, inconsistent transformation data can result, however, which

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means that the transformation matrices of the first time point do not
match the stress results of the subsequent points in time. Therefore, a
model change should be avoided in this case.
4. The last increment of the step is imported from an ABAQUS file format
(*.fil and *.odb) when the default settings are used. The switch
"Increments: Only last per step" must be deactivated to import results
from the several step increments. The same behavior also applies for
ESI ERF-HDF5, whereby the button is called “Time Steps: Only last
New time step per load case”. This applies for all time steps in a load case.
5. With ABAQUS odb the “Incl. Increment 0” button can be used to set
whether or not the zero increment should be taken into account. The
default setting is for it not to be counted.
6. ESI ERF-HDF5: If the “Incl. time steps with time of 0.0” button is
New enabled, all the time steps with a time of 0.0 are also included.

Figure 11 - Stress-format specific options

2.3.1.2.2 Load case

As mentioned above, only one load case per channel can be considered. For
this reason, the classification number of the load case relevant to the current
channel must be entered in the "LC" box.
Depending on the interface you must either enter the load case number
contained in the header of the load case (Nastran Punch, I-DEAS MS
Universal, Cosmos/M), or the sequential number of the load case starting with
1 in the stress file (Medina, Nastran op2, Abaqus fil, Ansys rst, LS-Dyna
d3plot, Marc t16, Permas post, Abaqus odb, Altair h3d, ESI ERF-HDF5). The
load case number entered is ignored in formats that can only have one load
case per file (Ansys presol, Patran rpt, Pro/Mechanica). If the load case
numbers are unknown you can select the load cases for most interfaces via a
selection dialog (except for Nastran Punch, I-DEAS MS Universal, Cosmos/M.
For instance, they can be determined while scanning the file with FEMFAT
basic, since information regarding the stress data records found in the file is
output here. Otherwise, the desired load case number must be searched for
directly in the file by using an editor. For stress data in MS Universal format
this is the entry in the first row after the record header with the ID 2414 . In
addition, it should be noted that Universal files do not strictly use a load case
number; instead an analysis record number is specified.)
By entering a value in the Factor box, the result saved in the stress file can be
multiplied and thus adjusted to real load situations. This factor has no influence
on the information written into the scratch files, i.e. changing the factor does
not require repeated scratching!

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2.3.1.2.3 Load history

One load history record must be defined per channel, which gives a factor for
every point in time and with which the previously read stress data set is to be
multiplied.
The load history can be acquired by various means, e.g. measurement or
simulation with Multi-Body System (MBS) applications such as ADAMS.
Simple constant (e.g. for bolt pre-stresses and residual stresses), sinusoidal and
triangular histories can be defined directly. Possible types of input are history
files in the file formats offered or synthetic histories:

ADAMS Request File

RPC ASCII file
TecMath ASCII file
DIAdem Data file
ADAMS spreadsheet FIL file
RPC Binary file
nCode DAC file
Constant
Cosine
Triangle

Example of load history in the file format of the ADAMS Request file
A.R2 00.00.00 01-Apr-95 0 0 3D

3 M_KGS_N_RACA 1.0
101 5 0 0 6
Fxl Fyl Fzl Mxl Myl Mzl
102 5 0 0 6
Fxr Fyr Fzr Mxr Myr Mzr
103 5 0 0 6
Fed_li Fed_re LenkHub Acc_li Acc_re
0.00000E+00
0.25308E+03 -0.11309E+03 0.53674E+04 0.99737E+02 0.16443E+02 -0.18429E+02
0.22955E+03 0.18597E+03 0.54183E+04 -0.43911E+02 0.26190E+02 0.81343E+00
0.00000E+00 0.00000E+00 -0.18024E-02 -0.12143E+01 0.15978E+01 0.00000E+00
0.32000E-02
0.26877E+03 -0.13285E+03 0.53833E+04 0.11239E+03 0.20246E+02 -0.20562E+02
0.25403E+03 0.18765E+03 0.54566E+04 -0.47561E+02 0.29597E+02 0.19152E+01
0.00000E+00 0.00000E+00 -0.36813E-02 -0.76693E+00 0.18534E+01 0.00000E+00
0.64000E-02
0.28259E+03 -0.15090E+03 0.53967E+04 0.12395E+03 0.24021E+02 -0.22566E+02
0.27192E+03 0.18765E+03 0.54924E+04 -0.50369E+02 0.32964E+02 0.30072E+01
-0.12207E-03 -0.12207E-03 -0.44522E-02 -0.44738E+00 0.18534E+01 0.00000E+00
0.96000E-02
0.29393E+03 -0.16608E+03 0.54055E+04 0.13384E+03 0.27740E+02 -0.24344E+02
0.28333E+03 0.18525E+03 0.55240E+04 -0.52011E+02 0.36255E+02 0.40790E+01
-0.12207E-03 0.00000E+00 -0.45345E-02 -0.63911E-01 0.15978E+01 0.00000E+00
0.12800E-01
0.30335E+03 -0.17774E+03 0.54088E+04 0.14195E+03 0.31375E+02 -0.25826E+02
0.29212E+03 0.18022E+03 0.55507E+04 -0.52541E+02 0.39433E+02 0.51239E+01
0.00000E+00 0.00000E+00 -0.44467E-02 0.31956E+00 0.95867E+00 0.00000E+00
0.16000E-01

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0.31180E+03 -0.18574E+03 0.54063E+04 0.14844E+03 0.34897E+02 -0.26990E+02
0.30101E+03 0.17276E+03 0.55716E+04 -0.52249E+02 0.42455E+02 0.61388E+01
0.00000E+00 -0.12207E-03 -0.43870E-02 0.57520E+00 -0.63911E-01 0.00000E+00
0.19200E-01
0.31966E+03 -0.19069E+03 0.53979E+04 0.15344E+03 0.38280E+02 -0.27847E+02
0.30988E+03 0.16346E+03 0.55864E+04 -0.51498E+02 0.45280E+02 0.71231E+01
0.00000E+00 0.00000E+00 -0.43709E-02 0.83084E+00 -0.19173E+00 0.00000E+00
0.22400E-01
0.32659E+03 -0.19360E+03 0.53842E+04 0.15710E+03 0.41499E+02 -0.28433E+02
0.31603E+03 0.15313E+03 0.55947E+04 -0.50588E+02 0.47868E+02 0.80772E+01
-0.12207E-03 -0.12207E-03 -0.43726E-02 0.70302E+00 -0.70302E+00 0.00000E+00
etc.

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Example of load history in the file format of the RPC ASCII file
The RPC ASCII format load history file can contain a header of any length,
which is concluded by the key word END_OF_HEADER. The data then
follows in columns.
The columns are separated by delimiters (e.g. spaces). A decimal point is
represented by a period.
This format can be created with any multi-body system and measurement-data
application, text editor or spreadsheet application.

FORMAT = ASCII
NUM_HEADER_BLOCKS = 9
NUM_PARAMS = 35
FILE_TYPE = TIME_HISTORY
DATA_TYPE = SHORT_INTEGER
TIME_TYPE = RESPONSE
DELTA_T = 0.003333333
PTS_PER_FRAME = 1024
CHANNELS = 2
PTS_PER_GROUP = 2048
BYPASS_FILTER = 0
HALF_FRAMES = 0
REPEATS = 1
FRAMES = 3
SCALE.CHAN_1 = 0.0003053248657
UPPER_LIMIT.CHAN_1 = 1
LOWER_LIMIT.CHAN_1 = -1
MAP.CHAN_1 = 1
SCALE.CHAN_2 = 0.0003053248657
UPPER_LIMIT.CHAN_2 = 1
LOWER_LIMIT.CHAN_2 = -1
MAP.CHAN_2 = 2
PARTITIONS = 1
PART.CHAN_1 = 1
PART.NCHAN_1 = 2
DESC.CHAN_1 = WAVE 1
UNITS.CHAN_1 = E
DESC.CHAN_2 = WAVE 2
UNITS.CHAN_2 = E
DATE = 07-Feb-2000 12:31:11
OPERATION = FEMFAT LAB data conversion
PARENT_1 = D:\WORK\\WAVE.RMS
INT_FULL_SCALE = 32752
TOTAL_PTS_PER_CHAN = 3072
DATA.FORMAT = (8(G14.8,2X))
END_OF_HEADER
-.49462631E-01 -.88544218E-02
-.96787989E-01 0.00000000
-.14075477 0.91597466E-02
-.17983635 0.18319493E-01
-.21220079 0.27479239E-01
-.23662679 0.36638986E-01
-.25250366 0.45798734E-01
-.25891548 0.54958478E-01
-.25525159 0.63812897E-01
-.24151199 0.72972648E-01
-.21769664 0.82132392E-01
-.18441623 0.91292143E-01
-.14258672 0.10045189
-.92818767E-01 0.10961163
-.36333662E-01 0.12732047
0.90070836E-01 0.16426478
0.15663166 0.18288961
etc.

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Example of load history in the file format of the TecMath ASCII file

BEGIN
COLUMN WIDTH = [ 13, 13, 13]
COLUMN OFFSET = [ 0, 2, 2]
CHANNEL NAME = ['dome force', 'side force', 'braking force']
LENGTH = [33633,33633,33633]
UNIT = [' ','
',' ']
MINIMUM = [-4.29687e+02,-3.92187e+03,-1.06250e+04]
MAXIMUM = [1.890630e+04,1.365630e+04,1.289060e+03]
START = [ 0.00000e+00, 0.00000e+00, 0.00000e+00]
DELTA = [ 1.00000e+00, 1.00000e+00, 1.00000e+00]
#Global file data

#Channel-specific data for channel 1

# Channel-specific data for channel 2
# Channel-specific data for
channel 3
END
6.01562e+03 3.90625e+01 7.81250e+00
6.01562e+03 4.68750e+01 1.56250e+01
5.99609e+03 3.90625e+01 1.56250e+01
6.01562e+03 5.46875e+01 1.56250e+01
5.99609e+03 5.46875e+01 1.56250e+01
6.01562e+03 5.46875e+01 2.34375e+01
6.01562e+03 5.46875e+01 7.81250e+00
6.01562e+03 6.25000e+01 1.56250e+01
6.01562e+03 7.03125e+01 1.56250e+01
6.01562e+03 6.25000e+01 0.00000e+00
6.01562e+03 6.25000e+01 -7.81250e+00
6.01562e+03 7.03125e+01 -7.81250e+00
6.01562e+03 7.81250e+01 -1.56250e+01
6.01562e+03 6.25000e+01 -3.12500e+01
6.03516e+03 7.03125e+01 -7.81250e+00
6.01562e+03 6.25000e+01 -1.56250e+01
6.01562e+03 6.25000e+01 -1.56250e+01
6.03516e+03 7.81250e+01 -7.81250e+00
6.01562e+03 7.81250e+01 -7.81250e+00
6.01562e+03 8.59375e+01 7.81250e+00
6.03516e+03 7.03125e+01 7.81250e+00
6.03516e+03 6.25000e+01 1.56250e+01
6.01562e+03 7.81250e+01 1.56250e+01
6.03516e+03 8.59375e+01 2.34375e+01
6.01562e+03 8.59375e+01 1.56250e+01
6.01562e+03 8.59375e+01 2.34375e+01
6.03516e+03 7.81250e+01 3.12500e+01
6.01562e+03 7.03125e+01 3.12500e+01
6.01562e+03 7.03125e+01 2.34375e+01
6.01562e+03 7.81250e+01 2.34375e+01
6.03516e+03 8.59375e+01 2.34375e+01
6.03516e+03 7.81250e+01 3.12500e+01
6.03516e+03 7.03125e+01 3.12500e+01
6.01562e+03 5.46875e+01 2.34375e+01
6.03516e+03 6.25000e+01 2.34375e+01
6.03516e+03 7.03125e+01 2.34375e+01
6.03516e+03 6.25000e+01 2.34375e+01
6.03516e+03 6.25000e+01 1.56250e+01
6.05469e+03 7.03125e+01 2.34375e+01
6.05469e+03 5.46875e+01 2.34375e+01
6.03516e+03 6.25000e+01 1.56250e+01
6.03516e+03 7.81250e+01 2.34375e+01
6.03516e+03 7.03125e+01 -7.81250e+00
etc.

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Example of load history in the file format of the DIAdem Data file

15.01.1993 05:47:19, 1, 1, 6, 2.10, 3.34

15.01.1993 11:32:03, 2, 2, 14, 7.50, 6.65
15.01.1993 16:56:24, 3, 3, 22, 5.70, 4.98
16.01.1993 06:05:31, 1, 4, 6, 1.30, 2.37
16.01.1993 11:51:38, 2, 5, 14, 10.20, 1.12
16.01.1993 17:15:57, 3, 6, 22, 5.90, 2.69
17.01.1993 06:02:27, 1, 7, 6, 3.40, 3.72
17.01.1993 11:12:55, 2, 8, 14, 4.60, 1.89
17.01.1993 17:51:41, 3, 9, 22, 0.50, 6.47
18.01.1993 05:35:05, 1, 10, 6, 2.90, 9.15
18.01.1993 11:14:48, 2, 11, 14, 5.00, 3.29
18.01.1993 16:54:41, 3, 12, 22, 4.40, 1.54

If a load history file is to be created with DIAdem software, a few of the file
format settings must also be performed with DIAdem in order to allow the file
to be read by FEMFAT.

Because FEMFAT only reads the data file, but not the header files that
contain the descriptions and formats of the data in the database, the followings
preferences must be specified:

required
Key number Key number function Explanation
setting
Save data Block orientated
213: BLOCK data saving

214: Data type ASCII ASCII data format

Pointer to the first Read from row 1
221: 1
channel value
Delimiter for ASCII Comma as
230: 44
block data delimiter
Decimal separator in Period as decimal
231: 46
ASCII files point
240: Start value/offset 0 Offset 0
Increment/ Factor 1
241: 1
calibration factor

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Example of a load time characteristic in ADAMS spreadsheet file format

The load time characteristic file in ADAMS spreadsheet format is similar to the
RPC ASCII file.
A header of any length first appears. FEMFAT searches for the keyword
TIME. The data then follows in columns.
The columns are separated by delimiters (e.g. spaces). A decimal point is
represented by a period.

etc.

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Load time characteristic data in RPC binary format

The format of the RPC binary files is not described further here.
This format can, for example, be created using a measurement-data program or
the MBS ADAMS application.

After selecting the file format you need to enter the file name including the
path of the load history file of the current channel in the Load History File
column.
This file may contain more than just one history. However, each channel can
only be assigned one history.
The manner in which several load histories are saved in one file is format-
dependent and can be in columns or blocks:
Format Saved in
ADAMS Request File blocks
RPC ASCII file columns
TecMath ASCII file columns
DIAdem Data file columns
ADAMS spreadsheet file columns
RPC binary binary format
nCode DAC file binary format

Illustrative example (not a common file format) for block-saving:

12 channels are saved in data blocks with three rows and four columns each.
The necessary channel information is found in the second row and fourth
column of every block.
CHANNEL 8:
Time = 0.00 Value = 8.5400
Time = 0.10 Value = 2.3861
.......
.......
0.00 (= time) Column 1 Column 2 Column 3 Column 4
Row 1 4.5105 8.5108 2.6840 6.6840
Row 2 8.5871 1.6840 9.5403 8.5400
Row 3 8.3540 5.6401 4.6880 0.6540

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0.10 (= time) Column 1 Column 2 Column 3 Column 4

Row 1 1.7340 2.3819 1.3377 2.1109
Row 2 7.3861 1.0596 2.5219 2.3861
Row 3 2.3599 1.9391 1.7679 0.6603
... and so on for all time increments.

"Row" in block
In this case enter
"2"
to select the required entry in row 2.

Column "Col" in block

For the example shown above, enter
"4"
to select the required entry in column 4.

2.3.1.2.4 Scratch files

The scratch files are necessary for ChannelMAX to save intermediate
results concerning the channel load to the hard drive. One scratch file is created
per channel.
For base material nodes, the scratch files contain node-averaged stress results.
For FEMFAT weld, the element stresses determined at the assessment point
are also saved in the weld coordinate system. If a force-based weld evaluation
method is employed (SSZ or MSZ method, see FEMFAT weld user manual
Chapter 4.1.2.4), the line loads are also stored. This will be done for weld
nodes (node color 100-109) independently if the WELD module is switched
ON or OFF. This information is only available in the scratch files for all nodes
of the current analysis group.
When a force-based spot weld analysis method is used (see the FEMFAT
spot manual, Chapter 3), the node forces at the respective spot weld nodes
are stored in the scratch files.
Note: Scratch files are intended for internal processing within the program
during the analysis and therefore, their suitability for reuse in other calculations
is limited.
At first, between the two data formats in the SRC column,
• ASCII file (large, but portable)
• binary file (smaller, but not portable)
must be selected. Afterward, the file name including the path can be entered in
the Scratch file input field in the event that the file names suggested are not to
be used.

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The scratch files are created for the current analysis group. Editing of the
analysis group after creating the scratch file leads to errors during the analysis
if nodes are added to the analysis group (reducing the size of the analysis
group, on the other hand, does not require a new scratch file).

2.3.1.3 Importing the MAX input file

An existing MAX input file, which was created at a previous ChannelMAX
session, can be imported into the program. This is done by selecting the file in
the dialog which can be opened using the Import button.
This input file differs from the FEMFAT Job File (*.ffj), which contains all
commands and input of the FEMFAT session.
As mentioned above, ChannelMAX requires the corresponding finite
element stress distribution and history for each channel. The name of the
corresponding files, together with additional information such as the load case
number, (channel) load factor,... (see Chapter 2.3.1.1 Creating a new channel)
can be saved in a MAX input file. This means that a MAX input file does not
contain any stresses or histories!

Example of a MAX input file

-1
1001
Management of Unit-Stresses
Text:
Text:
Text:
Text:
Channel-label : 1
Status : on
File-name : MAX_model1_bending.unv
File-format (2-31): 4
Load-case-number : 2
Load-factor : 1.0000E+00
-----------------------------------------------------------
Channel-label : 2
Status : on
File-name : MAX_model1_torsion.unv
File-format (2-31): 4
Load-case-number : 5
Load-factor : 1.0000E+00
-----------------------------------------------------------
-1
-1
1002
Management of Load-Histories
Text:
Text:
Text:
Text:
Channel-label : 1
File-name : MAX_model1_history.rpc
File-format (2-11) : 3
Row in data-block : 1
Column : 1
-------------------------------------------------------------
Channel-label : 2
File-name : MAX_model1_history.rpc
File-format (2-11) : 3
Row in data-block : 1
Column : 2
-------------------------------------------------------------
-1
-1

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1003
Management of Scratch-Files
Text:
Text:
Text:
Text:
Channel-label : 1
File-name : bending.scr
File-format (1-2) : 1
-------------------------------------------------------------
Channel-label : 2
File-name : torsion.scr
File-format (1-2) : 1
-------------------------------------------------------------
-1
-1
1004
Management of Analysis-Parameters
Text:
Text:
Text:
Text:
Angle between cutting-planes (degree) : 10.0
Cutting-plane-filter-method (0-2) : 1
Channel stress filter limit for method 1 (p.c.) : 99.9
Upper-stress-filter-limit for method 1 (p.c.) : 99.9
Lower filter-limit for method 2 (per cent) : 1.0
Upper filter-limit for method 2 (per cent) : 30.0
Number of rainflow classes : 64
Factor for residue load cycles : 0.500
-------------------------------------------------------------
-1

If definitions of synthetic load histories exist, they are written into the MAX
input file as a separate record.

-1
10021
Management of Synthetic Load Histories
Channel-label : 1
Format : 9
NumberOfSamples : 0
Factor : 1.000000
--------------------------------------------------------------------------------
Channel-label : 2
Format : 10
NumberOfSamples : 0
PhaseShiftPoints : 0
PointsPerWave : 2
Amplitude : 1.000000
Mean : 0.000000
--------------------------------------------------------------------------------
Channel-label : 3
Format : 11
NumberOfSamples : 0
PhaseShiftPoints : 0
PointsPerWave : 2
Amplitude : 1.000000
Mean : 0.000000
--------------------------------------------------------------------------------
Channel-label : 4
Format : 11
NumberOfSamples : 0
PhaseShiftPoints : 0
PointsPerWave : 2
Amplitude : 1.000000
Mean : 0.000000
--------------------------------------------------------------------------------
-1

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2.3.1.4 Writing to the MAX input file

The names of the files, together with additional information such as load case
ChannelMAX number, load factor (see Chapter 2.3.1.1 Creating a new channel), which
input file define a channel can be saved in a ChannelMAX input file, for which use
*.max of the *.max extension is recommended. Do so by clicking on the Export
button.
This file can be used for further FEMFAT sessions.

2.3.1.5 Importing the load histories

Press "Read/create" to import or generate the load history. Progress is
displayed as a percentage in the corresponding box.

2.3.1.6 The signal generator in ChannelMAX

A signal generator for generating synthetic load histories is available in the
ChannelMAX module.

If a channel is selected in the ChannelMAX table and the drop-down box

for selecting the load history file format is opened, three options for generating
synthetic load histories are available in the drop-down box.

Figure 12 - History selection in ChannelMAX

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1.) Defining a constant load history:

Figure 13 - Defining a constant load history

2.) Defining a cosine-form load history.

Figure 14 - Defining a cosine-form load history

3.) Defining a triangular load history.

Figure 15 - Defining a triangular history

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If load histories are defined in files the number of sampling points in the file is
automatically used by the signal generator. If this is not the case the number of
sampling points required is queried in a dialog box before the synthetic load
histories are created.
Synthetic load histories are generated in the same way as load histories from
files when the Read/Create load history data button is pressed.
This button must also be pressed in order to allow visualization of a load
history.
Synthetic load history definitions are also stored in the MAX input file, and
they can be easily re-imported into FEMFAT in this manner (see Chapter
2.3.1.3 Importing the MAX input file).

2.3.1.7 Compressing load histories

It is possible to perform a load data reduction by compressing the load history.
After the load histories have been imported, the compression dialog box can be
opened (see Figure 18).
Data reduction is by one of two methods:
• Disregarding intermediate points:
Generally speaking, only the cuspidal points of the load history are
important for rainflow counting. All points between have no or only a
minor influence on the damage result. All times at which no channel
displays a cuspidal point can therefore be ignored. As soon as one single
channel has a cuspidal point, the time is taken into consideration. In this
way, a history compression is possible, which in most cases has almost no
influence on the damage.

Figure 16 - Disregarding intermediate points for one channel

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Figure 17 - Disregarding intermediate points for more than one channel

• Disregarding small partial cycles ("omission"):

Small amplitude partial cycles can be disregarded by entering a limit
value. This smooths the load history.
Three options are available for defining the differential load limit value for
filtering:
1. The filter limit of a given channel is specified as a function of the
maximum differential load for that channel (difference between the
maximum and minimum load during the time history), regardless of
other channels. The limit value for the nth channel is acquired from:
Limit value(n) = Differential load(n) ⋅ g
g....relative load history limit [%], user-definable in the GUI.
2. Determination of limit value based on the critical channel:
Two options are available for finding the filter limit:
a.) The most critical channel has the greatest product of channel factor
and max. absolute load value of all channels. The filter limit is a
function of the most critical channel k, taking the channel factor of
the nth channel into account:
channel_fa ctor ( k )
Limit _ value ( n ) = load ( k ) ⋅ ⋅g
channel_fa ctor ( n)
g....relative load history limit [%], user-definable in the GUI.

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b.) In order to determine the most critical channel, taking the channel
stress into consideration, the maximum load in the load history for
each channel is first searched for. The following data is then
multiplied for all nodes: the largest value force for the channel,
channel factor and stress tensor of the node in question. Then the
maximum Mises equivalent stress σMises for all nodes is searched
for every channel. The channel with the greatest Mises stress (and
amplitude not zero) is the most critical channel k. The filter limit
for the nth channel is acquired from:
σ Mises (k )
limit _ value(n) = load _ difference(n) ⋅ ⋅g
σ Mises (n)
g....relative load history limit [%], user-definable in the GUI.

Only using the third method (2b) is it also possible to delete complete channels
if the stresses at these channels are not at all critical.
However, if a channel has a constant history (e.g. bolt pre-stress or residual
stress) it will not be deleted.
If the limit value is set to 0%, only the cuspidal points remain after
compression.
The relative load history limit is entered first. The default setting for this value
is 5%. The number of expected sampling points is shown by pressing the
button. A text file with the name "loadhistory_compression.dat"
containing those times actually remaining after compression is also created in
the working folder. The button must now be pressed to complete
the modifications to the imported history data.

Figure 18 – Compressing load histories

After compression the data can be exported to a file. Only the RPC-ASCII
format is currently available for this purpose.

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2.3.1.8 Working with modal stresses in ChannelMAX

In the damage assessment of vehicle and engine components, elastic multi-
body simulation (MBS) is increasingly applied. Usually, dynamic loads are
determined from this and, in a subsequent FEM analysis, the stresses
calculated. The damage analysis is performed using the FEM stresses.
However, this has the disadvantage that the stresses are quasistatically
simplified or that the amount of data can become much too large in transient
dynamic FEM analyses.
FEMFAT ChannelMAX provides the possibility of performing parallel
integration of FEM and MBS and operational strength analyses. The basis
of this method is the Component Mode Synthesis, which is already generally
accepted, to integrate flexible FEM models into the multi-body simulation (e.g.
ADAMS). Here, in addition to the displacement types (component modes), the
modal stresses (stress figures belonging to the component mode) are
calculated. According to the same principle with which the total displacement
in the MBS is compiled from the individual component modes, the total stress
in a damage analysis is compiled from the individual modal stresses. The
weighting factors for this super-position are taken from the MBS analysis.
This has the advantage that
• a fully dynamic damage analysis is performed without oscillation effects
being neglected, with all the possibilities of a non-linear MBS.
• transient histories of any length can be processed, whereby the necessary
data is barely larger than that required for a comprehensive FEM modal
analysis.
• the additional step of the FEM stress analysis in accordance with MBS
analysis is completely done away with and thus eliminates possible error
sources.

Procedure for a modal damage analysis

The part to be subjected to damage analysis must be integrated into the MBS as
a flexible body. Thus, we initially have a modal analysis (computation of the
natural frequencies and the mode shapes) of the FEM model of this body. In
addition to the component modes (displacement types), the stress distributions
(modal stresses) corresponding to the individual displacement types must be
calculated. The component modes represent the input values for the MBS.
The elastic deformation of the body is calculated in the MBS by temporally
weighted superpositioning of the component mode. This temporal weighting of
each mode represents its modal coordinate. The progression of the modal
coordinates of each mode is the result of the MBS.
The total stress of a body is calculated, in analogy to the elastic displacement,
from a temporally weighted superpositioning of the initially calculated modal
stresses. This temporal weighting corresponds to the progression of the modal
coordinates of the component modes as available as the results of the MBS.

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A modal stress and the temporal progression of this modal coordinate

correspond to one channel of a FEMFAT analysis. Therefore, as many
channels must be considered as modes were considered in the MBS.
The modal coordinate progression is processed as follows for FEMFAT: The
ADAMS MBS application generates a *.tab file.

In order to minimize file size, all unnecessary columns can be deleted with an
editor, as ADAMS also exports the rigid body modes and the 1st and 2nd
derivatives of the individual coordinates. This reduces the file to around one
third of the original size. The modal coordinates are found in columns Q7 –
Qx, whereby x represents the highest number of considered modes. The file
can be edited in FEMFAT in the Spreadsheet ADAMS format.
As an alternative, the modal coordinates can also be exported from ADAMS in
binary RPC3 format and edited in FEMFAT ChannelMAX.
Besides the channels for modal stresses and coordinates, additional channels
can also be defined (e.g. constant loads) in FEMFAT.

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2.3.2 TransMAX time steps

If fixed loads or non-linear effects occur, the TransMAX method for
operational strength analysis must be used. A FEM analysis result is required
for every point in time when using TransMAX.
The TransMAX input range basically consists of
• Definition of transient load cases
• Definition of the constant load case
• Analysis settings
• TransMAX data saving

2.3.2.1 Definition of transient load cases

When performing a TransMAX analysis, a separate stress data record must
be specified for each point in time. These stress data records are specified by
means of load case tables.

Fig. 19 - TransMAX load case definition table

Each row in the table corresponds to one or more load cases (a more detailed
description is provided later on). These load cases are arranged chronologically
from top to bottom in the table, i.e., if there is a load case for each row, the
load case for the first point in time will be in the first row, the load case for the
second point in time will be in the second row, etc.
In principle, this applies even if a row contains more than one load case.

The input field can be used to create new table tows –

either by directly entering the total number of desired rows or by using the
arrow keys to the right of the input field.

If a table has rows already and the number of rows is increased, FEMFAT
attempts to fill in the new rows with appropriate default values based on the
entries that have already been made (see autofill function further below). If the
number of rows is reduced, it is automatically assumed that the bottommost
table rows should be deleted, and a confirmation prompt requesting the user to
confirm the fact that the rows should be deleted is displayed.

There are three ways to directly delete a specific time step:

1. With the Delete switch, which is located above the table: the time step
specified on the input field to the left of the switch is deleted.

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Fig. 20 – Deleting time steps

2. With the Delete All switch which is located next to the import and
export switches: All time steps present in the table will be deleted.
3. A context menu appears after right-clicking on the table. This context
menu makes it possible to delete either the current table row, the
selected table rows or all table rows. The procedure used to select
several rows is the usual one, e.g., holding down the SHIFT key (to
select a range) or holding down the CONTROL key (multiple
selection).

Fig. 21 - Deletion context menu

The following information must be specified in every row in order to define the
load cases:
1. The data format in which the FEM stresses are available
("Format" column)
2. The file from which the stresses should be read
("Stress File" column)
3. The load case(s) that should be read from the stress file ("LC" column).

2.3.2.1.1 File format:

The file formats that can be processed in FEMFAT are similar to the model
data (for details, see the Interfaces manual).

Additional settings can be configured for some formats ("stress-format

specific options"):
1. Data allocation at element node or averaged at nodes: this option is
available for Nastran op2, Abaqus fil, Permas post and Altair h3d.
2. Reading node forces for WELD SSZ and SPOT CHexa: If this
checkbox is enabled, additional node forces for force-based weld
assessments and spot weld assessments can be read when using the
Nastran op2 and Medina formats. Since this option may require a lot of
memory, it should only be enabled if necessary.
3. Abaqus odb: Ignore inconsistent transformation data for a model
change: The default setting is for the stress data of all points in time to
always be transformed into the global coordinate system using the
transformation matrices of the first load case of the odb file defined for
the first time point. Transformation into the global coordinate system is
necessary so that during stress averaging at the node all stresses are
located in the same coordinate system. At the same time, for rotating

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components or components in motion or components with a great

degree of deformation, the coordinate system must be body fixed so
that the stress analysis in cutting planes delivers correct histories. This
is ensured with the default setting (button disabled). When a model
change has been performed, inconsistent transformation data can result,
however, which means that the transformation matrices of the first time
point do not match the stress results of the subsequent points in time.
The button can be enabled so that the TransMAX analysis can
nonetheless be carried out. Then the transformation of the stresses is
performed using the associated transformation matrices at the
respective time point. However, this assumes that the body does not
move and is not subject to a great deal of deformation.

Figure 22 - Stress-format specific options

2.3.2.1.2 Stress file

The file from which the load case data should be read can be specified either
directly in the input field or by means of a file browsing dialog. The input field
and the dialog switch are enabled after left-clicking once on the corresponding
table row.

Fig. 23 - Activated file selector field

2.3.2.1.3 Load case selection

The load case is selected by specifying the respective load case number. Only
one load case can be defined per table row.
For Abaqus fil, Abaqus odb or ESI ERF-HDF5 it is possible to define more
than one load case per table row for all of these formats. The selection of the
New load cases from the file is accomplished by specifying the step, increment,
step-increment range or time range for Abaqus fil and Abaqus odb, for
ESI ERF-HDF5 by specifying the load case, time step, load case- time-step
range or time range.

2.3.2.1.3.1 Specification by means of load case number

In the case of FEM formats in which the load case to be processed is specified
by means of a load case number, the latter is specified by entering the
corresponding number in the load case input field. The input field is enabled by
left-clicking once on the relevant cell.

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Fig. 24 - Activated load case selection field

Basically, care should be taken that the load case number entered is exactly the
same as that with which the required stress record was saved. With some
formats, this number is explicitly assigned by the generating program (Nastran
Punch, I-DEAS
DEAS MS Universal, COSMOS/M). With others, such as Nastran
op2, this number is determined automatically through the use a consecutive
consecutiv
number sequence (starting with 1), in ascending order, for all the stress data
records found in the file.
The load case number entered is ignored in formats that can only have one load
case per file (Ansys presol, Patran rpt, Pro/Mechanica). In addition, most
formats make it possible to use the context menu (which can be accessed by
right-clicking
clicking on one of the two input fields) to select the load case from a
dialog or to enter all the load cases found in the following file into the table
automatically (the
(the table is automatically made bigger if necessary), provided
the load case input field or stress file input field is enabled.
These two options are available when working with the Medina bof, Nastran
op2, Ansys rst, LSdyna d3plot, Marc t16, Permas post and Altair h3d formats.

Fig. 25 - Load case selection context menu

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Fig. 26 - Load case selection dialog

2.3.2.1.3.2 Specification by means of step, increment or point in

time or else load case, time step or point in time
This method is only available for the two Abaqus formats, i.e., fil and odb, as
well as ESI ERF-HDF5.
ERF
New In contrast to load case number entries, it is not possible to enter the
information directly into the load case input field. Instead, the context menu
(right-click
click on the input field) must be used to select one of the following
definition options (the load case input field must be enabled for this
purpose):
• Displaying stress records
• Display stress records - only last increment
rement (Abaqus) or last load case
(ESI ERF-HDF5)
ERF
• Step (Abaqus) or load case (ESI ERF-HDF5)
ERF
• Time

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Fig. 27 - Context menu for load case dialog and Step/Increment definition (Abaqus)

Fig. 28 – Context menu for load-case dialog and load case/time step definition
(ESI ERF-HDF5)

These definition options for Abaqus odb and fil are elaborated in more detail
below. The explanations apply analogously for the ESI ERF-HDF5 format,
whereby the following differences must be kept in mind:
• The designation “step” for Abaqus odb and fil corresponds to the
designation “load case” for ESI ERF-HDF5.
• The designation “increment” for Abaqus odb and fil corresponds to the
designation “time step” for ESI ERF-HDF5.
• With Abaqus odb and fil, the “Incl. increment 0” button in the Stress
Load Case Definition dialog can be used to set whether or not the zero
increment should be taken into account. With ESI ERF-HDF5 files, the
corresponding button (“Include time steps with time of 0.0”) allows
specification of whether or not time steps with a time of 0.0 should be
included.

2.3.2.1.3.2.1 Displaying stress records

When this option is used, a dialog that shows all the steps in the selected files,
including all the step increments for which there are matching results (i.e.,
"Stresses" result type, for instance), is opened. Once one of these increments is
selected from the list (only a single one can be selected), it is copied to the load
case input field.

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Fig. 29 - Step/Increment selection dialog

2.3.2.1.3.2.2 Displaying stress records - only last increment

Same as above, except that only the last increment of each step is shown and
made available for selection.

Fig. 30 - Step/Increment selection dialog (only last increment)

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2.3.2.1.3.2.3 Step
When selecting the step, a dialog that makes it possible to enter the following
data is opened:
• Step range, from/to: All the increments defined below and found in the
step range defined with this parameter are processed. If you want to
select a single step only, enter the same step number in both fields. To
select all the steps available, enter a number that is larger than the
number of steps in the file in the "to" parameter.
• Increments:
o All, every x increments: Selects all the increments that have a
matching result type and are found in the step range defined
above. If a 1 is entered for the parameter, every single increment
is selected; if a 2 is entered, every 2nd increment is selected; etc.
Last increment:
o Only the last increment of all the steps specified above is
selected.
Note: This is the default setting.
o Increment list: The desired increment numbers are entered
directly into the input field as a list (comma-separated) and/or as
a range (start number/end number). For example, entering 3,4,7-
9 selects increments 3,4,7,8 and 9 for all the steps specified
under "Step."
o Increment range from/to, every x increments: Selects all the
increments available within the specified step range, but only
within the specified increment range. If a 1 is entered for the
parameter, every single increment in the specified range is
selected; if a 2 is entered, every 2nd increment is selected; etc.

Fig. 31 - Step/Increment definition dialog

In other words, using this stress data record selection method makes it possible
to define more than one load case in a single table row. When making entries
with an increment list, it is also possible to select an increment multiple times

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(i.e., for several points in time), which would otherwise only be possible with a
new table row.

2.3.2.1.3.2.4 Time
When selecting time, a dialog that makes it possible to specify a time range is
opened. All increments that have a matching result type and timestamps (total
time) within the specified range are selected. If the start time that is set is the
same as the end time, the increment with a total time >= the specified time will
be selected.

Fig. 32 - Time range - definition dialog

2.3.2.1.4 Further possibilities for table handling

The table used to define transient load cases provides two options that can be
used to simplify and speed up entries, especially when a large number of load
cases is involved:
1. AutoFill - New table rows are filled out automatically
2. Filling with fill anchor - A table range is modified
These options are also available in the ChannelMAX table. Because of this,
the descriptions in page 16 regarding the options' basic functioning (especially
in regard to the format and file name being filled out automatically) also apply
to the TransMAX table. Due to its functioning principle, however, the
function used to automatically fill out the load case definitions works
differently from the way it does in ChannelMax, which is why a more
detailed description is provided below:

2.3.2.1.4.1 AutoFill - The load case column is automatically filled

out when a new row is created
If the new row is the first row, the load case definition is initialized with an
application-internal default setting (load case number 1 / step 1 / increment 1).
If it is not the first row, the value from the previous row is taken and
extrapolated as best possible to determine the load case value.
• If it is a load case number, it is always increased by 1 in comparison to
the previous number.
• If the previous row contains step/increment information without a step
range (i.e., the start step equals the end step), the step number is
increased by 1 in comparison to the previous one.
• If the previous row contains step/increment information with a step
range, the new row's start step is increased by 1 in comparison to the
end step of the previous row, and the end step of the new row is

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increased by an amount equal to the difference between the end step

and the start step in the previous row.
• If the row contains time information, the time is increased by 1 in
comparison to the previous time only if the start and end times are
identical and are also integers; otherwise, the previous time is carried
over unchanged (i.e., if the previous row is 2.0-2.0, for instance, the
new row is filled in with 3.0-3.0. If the previous row is 1.0-2.0, the new
row will also be 1.0-2.0; if the previous row is 1.1-1.1, the new row will
also be 1.1-1.1).

2.3.2.1.4.2 Automatic Modification of Load Case Definitions with

Fill Anchors
Load case definitions can be modified automatically within the current row and
the anchor row, provided there are no different FEM data formats within that
table range (if there are, the anchor functionality is disabled):

• If the definition is made with load case numbers, the load case number
from the current (modified) row and the load case number of the
previous row are used to generate a load case number jump used to
increase all load case numbers successfully, beginning with the current
row and ending with the anchor row. If, for instance, the load case
number in the current row is set to 5 and the load case number in the
previous row is 1, the jump will be 4, meaning that the next row will be
set to 9, the next one to 13, and so on (until the anchor row is reached).
If the first row is modified, there obviously will not be a previous row,
and the remaining rows will not be modified.
• If the load cases are defined with step/increment information, either an
attempt is made to find an adequate jump for modifying the following
rows (with a procedure similar to the one described above for load case
number modifications) or, in the event that the first row is modified, the
change made to the first row is carried over directly to all the following
rows all the way up to the anchor row.
• If a jump >= 1 is found between the start steps in the current row and in
the previous row, this jump will be added to all the following start and
end steps successively, relative to the current start/end step. The
increment values are carried over from the current row for all the
following rows.
• If no jump is found between the start steps in the current row and in the
previous row, but one is found in the increments (only possible when
defining increments with increment range input; not with the increment
list), the increment jump is added successively to the following rows all
the way up to the anchor row, and the start/end step values of the
current row are carried over directly to all the following rows.
• If the load cases are defined with time information, the anchor behavior
is similar to that used with the steps: an attempt to generate a jump
(even if it is not an integer) between the current row's start time and the

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previous row's start time is made so that it can be added successively to

all the following start and end times, relative to the current row.

Due to the large number of different entry and modification constellations, it is

recommendable to become more familiar with the anchor functionality -
especially in regard to step/increment information - by "trying it out."

2.3.2.2 Definition of the constant load case

It is also possible to consider constant stresses in TransMAX. The constant
stresses can be defined via a constant load case, which is then superimposed for
each load case/time of the transient load history. It is superimposed both for the
base material and for the WELD and SPOT nodes.
The constant load case is defined by means of the graphical user interface in
TransMAX. All interfaces implemented in FEMFAT can be used to import
the constant load case record. If the file for defining the constant load case
contains several load cases the required record can be selected from the
constant load case definition table. Furthermore, a general multiplication factor
can be specified for the constant load case. This is 1.0 by default.

Fig. 33 - Definition of the constant load case

2.3.2.3 Analysis preferences

Here preferences can be specified that apply globally for all time steps except
the constant load case.

Fig. 34 – Scratch-independent analysis settings

A multiplication factor (analogous to ChannelMAX) can be specified with

which all stresses or strains are multiplied. The main purpose of this option is
unit conversion/adjustment.
In addition, it is also possible to repeat the specified time range. The
previously defined analysis sequence is thus repeated using the factor given
here, i.e. if a factor of 100 was given in Number of Analyses Sequences in the
example above, it would correspond to a total number of 1,000 time points. Of
course, this only has any meaning for damage analyses. When performing an
endurance limit safety factor analysis, this value is reset to 1 (this also applies
if nonsensical values such as 0, e.g., are entered). The reasoning behind this
repetition factor is, for example, to calculate the stress data records of a
revolution for a position calculation and hence to perform a damage analysis
for a number of revolutions corresponding to the repetition factor (e.g. for 100

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revolutions). Because the residuum plays an important role, this avoids errors if
a large number of revolutions are to be extrapolated from the data of a single
revolution.
This factor has absolutely no effect on the scratch files or the gradient file,
i.e. it can be modified without needing to re-generate these files (expansion of
the times is not performed until during the analysis). However, the value
should only be set high enough to eliminate residual effects, as this
immediately influences the analysis time (values of magnitude 10 - 100
maximum should normally suffice). If, e.g., one would like to know the
damage caused by 100,000 revolutions, one should enter a value of 100 in
order to keep the residuum as small as possible and then multiply the damage
result by 1000.

When is a re-scratch necessary in TransMAX ?:

New scratch files must be generated if:
• the analysis group contains nodes that were not in the current group
when the scratch file was created (it is always the current group that is
scratched).
• the stress sequence has been altered by modifications to the time step
definition table or alterations in the external TransMAX input file.
• For subsequent modification of the automatic stress correction
preferences (FEMFAT automatically creates new scratch files before
analysis starts).
• For subsequent modification of the WELD assessment method (see the
FEMFAT weld user manual Chapter 4.1.2.4 for details).
• When activating or reactivating the boundary layer influence.

New scratch files need NOT be generated if:

• the active group at the time of scratching contains nodes that are not
contained in the analysis group (i.e. when reducing the size of the
analysis group a new scratch is not necessary).
• the number of analysis runs is altered.
• the general stress or strain multiplication factor is modified.
• analysis methods (WELD on/off, SPOT on/off, gradient influence
on/off,...) are altered, except for the boundary layer influence.

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2.3.2.4 Importing the TransMAX input file

An existing MAXT input file, which was created at a previous TransMAX
session, can be imported into the program. This is done by selecting the file in
the dialog which can be opened using the Import button.

Fig. 35 - TransMAX input data management

This input file differs from the FEMFAT Job Files (*.ffj), which contain all
commands and inputs of the FEMFAT session.
As noted above, TransMAX requires the respective FEM stress distribution
for every time step. The name of the corresponding file can be stored in a
MAXT input file together with the file format and the additional load case
number information. This means that a MAXT input file does not contain any
stresses or histories!
A MAXT file on the whole resembles a MAX file from the ChannelMAX
module.

2.3.2.5 Writing to the MAXT input file

TransMAX
The names of the files, together with additional information defined for the
input file time step, can be stored in a TransMAX input file for which we recommend
the file extension *.maxt. This is done by entering the file name in the dialog
*.maxt
which can be opened using the Export button.
This file can be used for further FEMFAT sessions (see Importing the
TransMAX input file).

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Example of a MAXT input file

-1
2005
Management of TransMAX Time Steps (Step/Inc/Time)
Text:
Text:
Text:
Text:
Data Location : 0
Data Type : 0
File Name : ff_HEAT_TEST_INTEGRAL_671.fil
File Format : 14
Setting Mode : 1
Step from : 1
Step to : 1
Inc mode : 999
------------------------------------------------------------
File Name : ff_HEAT_TEST_INTEGRAL_671.fil
File Format : 14
Setting Mode : 1
Step from : 2
Step to : 2
Inc mode : 999
------------------------------------------------------------
File Name : ff_HEAT_TEST_INTEGRAL_671.fil
File Format : 14
Setting Mode : 1
Step from : 3
Step to : 3
Inc mode : 999
------------------------------------------------------------
File Name : ff_HEAT_TEST_INTEGRAL_671.fil
File Format : 14
Setting Mode : 1
Step from : 4
Step to : 4
Inc mode : 999
------------------------------------------------------------
File Name : femfat_bsp_struktur_weld.op2
File Format : 10
Setting Mode : 3
Load Case : 2
Only Last Increment : true
------------------------------------------------------------
File Name : femfat_bsp_struktur_weld.op2
File Format : 10
Setting Mode : 3
Load Case : 3
Only Last Increment : true
------------------------------------------------------------
-1
-1
2006
Constant Load Case (Step/Inc/Time)
Text:
Text:
Text:
Text:
File Name : ff_HEAT_TEST_INTEGRAL_671.fil
File Format : 14
Setting Mode : 1
Step from : 5
Step to : 5

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Inc mode : 999

Stress Multipl. : 1.000000
-1
-1
2004
Management of Analysis Parameters
Text:
Text:
Text:
Text:
Number of Analysis Sequences : 1
Base Multiplication Factor Stress : 1.00000
Angle between Cutting Planes (Degree) : 10.0
Cutting Plane Filter Method (0-2) : 1
Channel Stress Filter Limit for Method 1 (p.c.) : 99.9
Upper Stress Filter Limit for Method 1 (p.c.) : 99.9
Lower Stress Filter Limit for Method 2 (p.c.) : 1.0
Lower Filter Limit for Method 2 (per cent) : 30.0
Number of Rainflow Classes : 64
Factor for Residue Load Cycles : 0.500
------------------------------------------------------------
-1

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2.4 Material data

For basic options for defining material data see the BASIC manual.

2.4.1 Material parameters required for

FEMFAT max
Basically, all FEMFAT max analyses require the same material parameters
like BASIC (for details see BASIC manual).
The following describes the material parameters required for special MAX
applications.

• Material data for the “Critical component reduced in critical plane”

method
o For creation of the shear Haigh diagram using the standard method:
New Shear strength, shear yield strength (optional), shear pulsating strength
(optional) and shear alternating strength in record 218 of the material
data ffd file
o User-defined shear Haigh diagram in record 217 of the material data ffd
file (optional)
o Slope and endurance cycle limit of the shear S/N curve in record 223 of
New the material data ffd file (optional)

• Material data perpendicular to the fiber direction in fiber reinforced

plastics
o Young's modulus (Ymin) [N/mm²]
o Ultimate tensile strength [N/mm²]
o Compressive strength [N/mm²]
o Tensile yield stress [N/mm²]
o Compressive yield stress [N/mm²]
o Tensile pulsating stress limit [N/mm²]
o Compressive pulsating stress limit [N/mm²]
o Alternating stress limit [N/mm²]
o Slope of the S/N curve
o Endurance cycle limit
o Cyclic coefficient of hardening [N/mm²]
o Cyclic exponent of hardening
o Strain at failure [%]
o Degree of orientation parallel to fiber
o Degree of orientation perpendicular to fiber
The following material parameters are absolutely necessary for evaluating fiber
reinforced plastics: .

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The following material parameters are calculated automatically if they are not
already defined: .
The following material parameters are assumed by parameters parallel to the
fiber direction, if they are not already defined: .
Further material parameters are utilized for the FEMFAT analysis, but they
cannot be defined perpendicular to the fiber direction. These parameters are
determined on the basis of ratios.
These parameters can be stored in a new record (no. 254) in the material data
file (*.ffd).

• Material data for continuous fiber-reinforced plastics

The following material data are used for the FEMFAT laminates module.
If the material data are not specified, the default values set in parentheses are
used:
o Slope pt⊥|| of the failure curve for normal stress >=0 (2D) (0.35)
o Slope pc⊥|| of the failure curve for normal stress <=0 (2D) (0.3)
o Weakening parameter s (2D) (0.5)
o Weakening parameter m (2D) (0.5)
o Slope p ⊥|| of the failure curve for normal stress >=0 (3D) (0.35)
t

New o Slope pc⊥|| of the failure curve for normal stress <=0 (3D) (0.3)
o Weakening parameter s (3D) (0.5)
o Weakening parameter m (3D) (0.5)
This concerns additional parameters of the failure curve according to Puck for
intermediate fiber breakage (2D) or delamination (3D). These can be stored in
a new record (no. 255) in the material data file (*.ffd).
Further parameters for FEMFAT laminates are stored in the previously
existing data sets:
o Static and cyclical parameters for loading longitudinally relative to the
fibers and shear are stored in records 218 and 223.
o Static and cyclical parameters for loading perpendicular to the fibers are
stored in record 254.
The analysis of failure due to delamination requires material data for tensile
New loading perpendicular to the laminate plane (σ33) and for interlaminate shear
force (τ31, τ32). These are stored in the new records 256 and 257.
Material data for tensile loading perpendicular to the laminate plane are (DS
256):
o Tensile strength
o Compressive strength
o Tensile yield stress
o Compressive yield stress
o Tensile pulsating stress limit

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o Compressive pulsating stress limit

o Alternating stress limit
o Slope of the S/N curve
o Endurance cycle limit
Material data for interlaminate shear force are (DS 257):
o Ultimate strength
o Yield stress
o Pulsating strength
o Alternating stress limit
o Slope of the S/N curve
o Endurance cycle limit

2.5 Node characteristics

For basic options for defining the node characteristics see the BASIC manual.

2.5.1 Process influence

Basically, all FEMFAT max analyses require the same node characteristics
like BASIC (for details see BASIC manual).
The following describes the node characteristics required for special MAX
applications.
The fiber orientation tensors can be defined in Microstructure Parameter in
order to take the fiber direction and degree of orientation into consideration.
The fiber orientation tensors originating from casting simulations can currently
New be imported using the MoldFlow XML and Digimat dof interfaces.
The fiber orientation tensors in the XML file are element-related. The fiber
orientation tensors are imported for all elements of the current group and
averaged at the nodes of these elements. As a control, the largest fiber
component of the current node is shown in the GUI.

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2.6 Influence factors

For basic options for defining the influence factors see the BASIC manual.
Basically, all FEMFAT max analyses require the same influence factors like
BASIC (for details see BASIC manual).
The following describes the node characteristics required for special MAX
applications.

2.6.1 General factors

Figure 36– Influence factors data form – general factors

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2.6.1.1 Stress gradient influence factor

Calculation of the stress gradient

A special procedure was developed for FEMFAT max for determination of
the stress gradient, as no generally recognized, multi-axial calculation concept
is available for stress gradient influence.
The stress gradient influence is estimated in four stages in ChannelMAX:
• Calculation of maximum amplitudes from load histories
• Calculation of the local von Mises equivalent stress for each channel
• Calculation of the appropriate relative stress gradient
• Superpositioning of the channel-referenced stress gradient to a
weighted stress gradient for each node
Following stages will be performed for TransMAX:
• Calculation of stress history of the three principal stresses
• Determination of maxima and minima of principal stresses histories
• These maxima will be combined with the corresponding minima. For
the resulting nine combinations the difference of the local stress tensors
and afterwards the von Mises equivalent stress amplitude will be
calculated. It is very probably that the combination with the maximum
amplitude represents the highest occurring stress cycle of the whole
stress history.
• This stress cycle will be used for calculation of the stress gradient
between the current node and its neighbor nodes.
• This procedure will be performed for each node, at which the time
stamps of the maximum and the minimum of the maximum stress cycle
may vary from node to node.
Due to the nature of multiaxiality, it is necessary to use a statistical method to
estimate the stress gradient influence. The precision of this result is a function
of the degree of multiaxiality.
If no gradients are considered, conservative results must be expected.

2.6.1.2 Mean stress influence factor

The main stresses to be considered result from rainflow classification of the
histories of resulting equivalent stresses in the cutting planes. This is why mean
stress information is usually not identical with the channel mean stress values.

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Illustrative example:
Three sinusoidal channel functions with constant parameters are given:
f (t) = A * sin (ν * ( t + ϕ )) + C
Parameters Channel 1 Channel 2 Channel 3
A...Amplitude 1 3 2
ϕ...Phase angle 45 30 90
C...Constant 11 -1 -5
ν...Frequency 12 9 3
Where t is the time.

Figure 37 - Three sinusoidal channel functions with constant parameters

The bold blue curve in the diagram shows the sum of the three channels. Even
in this special case of sinusoidal functions with constant parameters it can be
seen that the sum is no longer a simple sinusoidal curve with constant
parameters.
Moreover, in a case of non-proportional loading these parameters cannot be
derived from the determination of the mean channel parameter values:
Mean stress CHANNELS = constant
Amplitude CHANNELS = constant
Mean stress TOTAL ≠ constant
Mean stress TOTAL ≠ (MS 1 + MS 2 +MS 3 + ... + MS N ) / N
Amplitude TOTAL ≠ constant
Amplitude TOTAL ≠ (A 1 + A 2 +A 3 + ... + A N ) / N

2.6.1.3 Constant stresses

In order to facilitate consideration of a constant stress condition, it is possible
to define a separate channel with a constant channel history for
ChannelMAX. If these constant stresses are to be deactivated for the current

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problem, the corresponding channel load factor must be set to zero (see
Chapter 2.3.1.2.2 Load case).
It is also possible to consider constant stresses in TransMAX. The constant
stresses can be defined via a constant load case, which is then superimposed for
each load case/time of the transient load history. It is superimposed both for the
base material and for the WELD and SPOT nodes
The influence of the constant load case is only considered if the constant load
case check box is activated. If the influence factor is active and a constant load
case is defined, the stresses are superimposed for each component before the
analysis is carried out. The constant stress load case records are stored in the
stress scratch files.

2.6.1.4 FEMFAT plast (Stress Rearrangement)

Method of Analysis for the Influence of Mean (and Amplitude) Stress
Rearrangement
During classification of equivalent stresses in the cutting planes, the
information on the sequence of occurring mean and deflection stresses is lost.
If problems occur in the interpretation of the mean stress influence, recall the
sequence of events for multi-axial operational strength analysis in FEMFAT
max. The mean stress to be considered is obtained from rainflow
classification of the histories of equivalent stresses in the cutting planes. This
why the resultant mean stresses are generally not the same as the mean values
of the channel mean stress values.
Chapter 2.6.1.2 Mean stress influence factor gives a simple example as an
illustration.

2.6.1.5 Influence of rotating principal stress

The critical cutting plane method is not always sufficient to describe the
damage behavior of ductile materials. The damage result can be too optimistic
for rotating principal stresses. By enabling the "Rotating Principal Stresses
Influence" switch, the endurance limit is correspondingly modified as a
function of the degree of multiaxiality. The computation time, however, can be
substantially lengthened due to the necessary calculation of the degree of
multiaxiality.

2.6.1.6 Boundary layer

In ChannelMAX and TransMAX this factor must be enabled before the
scratch file is created so that the interpolated stresses can also be written to the
scratch file. Apart from that, this factor has no effect on the analysis results.

2.6.1.7 Influence of fiber orientation

A method for the damage analysis of short glass fiber reinforced components is
available in FEMFAT. The method was developed in cooperation with the
University of Leoben (Prof. Eichlseder), BMW Munich and EMS-Grivory and

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is based on local stresses and local S/N curves. The stress direction-dependent
material properties are taken into consideration for the operational life forecast.
The following additional steps are required:
• Importing the fiber orientation tensors for considering the fiber
direction and the degree of orientation.
• Definition of material parameters parallel and perpendicular to the fiber
direction.
• Activating the influence factor switch Fiber Orientation under
General Factors for considering the material anisotropy when doing
the damage analysis. This influence factor is only available for the
FEMFAT max module.
The fiber orientation tensors were defined as node characteristics for
consideration of the fiber direction and the proportion of fibers. The fiber
orientation tensors originating from casting simulations can currently be
New imported using the MoldFlow XML and Digimat dof interfaces.
Consideration of the material anisotropy in FEMFAT MAX module is done
by means of the critical cutting plane method. For each cutting plane the local
material properties are calculated based on the fiber orientation and fiber
components, and based on the location of the cutting plane normal vector.

2.6.1.7.1 Analysis procedure

The analysis component for evaluating short-fiber reinforced plastics is only
available in the FEMFAT max module, because the method is based on the
method of critical cutting planes implemented in FEMFAT max.
The following steps are performed for each node during the analysis:
• Calculation of the principal fiber directions and fiber components.
- Principal fiber directions = orientation tensor eigenvectors.
- Fiber proportion = orientation tensor eigenvalues.
• Calculation of the local material parameters in the main directions of
the anisotropy by inter-/extrapolation between given material
parameters parallel and perpendicular to the fiber direction. They are
used for creating the material parameter interpolation area for cutting
plane related material parameters.
• Cutting plane filtering – based on 1/safety factor.
• Operations per interesting cutting plane.
- Transformation of the current cutting plane-normal vector into
the fiber coordinate system.
- Calculation of the local material parameters in the current
cutting plane.
- Damage/safety analysis.
• Summation of partial damages

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2.6.1.7.2 Calculation of the local material parameters in the

current cutting plane
An ellipsoid-like, closed, three-dimensional symmetrical plane based on the
material parameters in the three principal anisotropy directions (e1, e2, e3) is
first created for calculation of the local material parameters in the current
cutting plane. The 3 parameters (w1, w2, w3) of the three-dimensional plane in
the three principal directions are determined by linear inter-/extrapolation on
the basis of the degrees of fiber orientation (λ1, λ2, λ3). The material
parameters parallel and perpendicular to the fiber direction are used for
interpolation. Once the three-dimensional plane has been created the normal
vector (v(x,y,z)) of the current cutting plane is transformed into the local
coordinate system (corresponds to the principal fiber directions). The
intersection of the three-dimensional plane with the cutting plane normal vector
is then calculated. This intersection gives the local material parameter (wv) in
the current cutting plane.

Figure 38 - Calculation of the local material parameters in the current cutting plane

Investigations at the "Institut für Allgemeinen Maschinenbau" at the University

of Leoben have shown that an interpolation of material parameters between the
specified parameters parallel and perpendicular to the fiber orientation on a
logarithmic scale correspond best to the test. Only the two methods Linear
interpolation and Logarithmic interpolation are offered.

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2.6.2 WELD / SPOT / LAMINATES

2.6.2.1 WELD

Figure 39 – Influence factors data form – WELD

2.6.2.1.1 WELD module switch

By default, the main switch for this module is deactivated. Activation has the
effect of causing all FEM nodes explicitly identified in the FEM preprocessor
or in VISUALIZER according to the weld modeling guideline for
FEMFAT weld (see FEMFAT weld user manual Chapter 2 - Modeling
of FEM weld entities) to be subjected to a separate weld evaluation.
The switch can only be enabled if the used license file contains a valid
FEMFAT weld license.

There are four parameters for specification of weld fatigue:

• Evaluation method
• Influence of load flow
• Sheet thickness influence
• Compressive stress reduction

It is also possible to select different assessment methods. Selection is by means

of a pull-down menu (see Figure 39). The default method is FEMFAT 4.7.
Details on the various methods can be taken from the FEMFAT WELD user
manual Chapter 4.1.2 FEMFAT-WELD assessment methods.

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2.6.2.1.2 Compressive stress reduction

In MAX the equivalent stress is first established from the stress components
and then the compressive stress reduction applied to the equivalent stress.

2.6.2.1.3 Equivalent stress

8 equivalent stresses are available in FEMFAT weld for the evaluation of
weld middle nodes and 4 equivalent stresses for start/end nodes.
The following equivalent stresses and equivalent safeties can now be selected
in FEMFAT max for evaluation of the weld middle nodes (attention: in
contrast to BASIC these are not constant amplitude structural stresses, but are
time-dependent notch stresses!):

σ V = sign(σ ⊥ ) σ ⊥2 + σ ||2 − σ ⊥ ⋅ σ || + 2τ 2
Equation 1: Equivalent stress according to DIN 15018 (default setting)

σV = σ ⊥
Equation 2: Equivalent stress corresponds to the normal stress perpendicular to the weld

σ V = σ ||
Equation 3: Equivalent stress corresponds to the normal stress parallel to the weld

σV = τ
Equation 4: Equivalent stress corresponds to the shear stress

σ V = sign(σ ⊥ ) σ ⊥2 + σ ||2 − σ ⊥σ || + 3 ⋅ τ 2
Equation 5: Mises equivalent stress

σ V = sign(σ ⊥ ) MAX (σ ⊥2 , σ ||2 ) + τ 2

σ V = sign(σ || ) MAX (σ ⊥2 , σ ||2 ) + τ 2

Equations 6 and 7: Equivalent stress (or safety factor) acc. to BS 7608

aV = a⊥2 + a||2 + f ⋅ a⊥ ⋅ a|| + aτ2

=> equivalent damage: DV = aVkeff
Equation 8: Equivalent utilization factor (or safety factor) acc. to DVS 1608

For more information regarding the service life evaluation of weld joints please
read the WELD manual.
Equivalent stresses for the SOLID WELD method
New With this method that is currently only available for ChannelMAX, a
relatively coarse volume mesh without rounding radiuses is used to assess the

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weld roots and toes by means of a critical distance method. This entails
determination of the stresses at a certain depth (which can be specified by the
user) by means of interpolation and comparison against a master S/N curve that
is based on numerous trials.
Details on the individual aspects of a SOLID WELD analysis can be found in
the FEMFAT WELD manual (see Section 2.2.2.2).

Five equivalent stresses are available for volume-based weld assessment using
the SOLID WELD method.
• Automatically
• Normal Stress in Critical Cutting Plane
• Signed Mises stress 1
(sign from max. principal normal stress)
• Signed Mises stress 2
(sign from hydrostatic stress)
• Max./min. principal stress
• Scaled normal stress

These equivalent stresses are calculated in the same way as for the base
material. A description of this can be found in Section 2.8.2.1.SPOT
For basic information regarding the definition/assessment of spot joint nodes
please read the BASIC /SPOT manual.

2.6.2.2 LAMINATES

New

Figure 40 – Influence factors data form – LAMINATES

LAMINATES is a module for the analysis of continuous fiber-reinforced

New plastics that is available in ChannelMAX. A license is required for its use. If

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the LAMINATES button is enabled (see Figure 40), the program branches to
the LAMINATES analysis component for nodes on shell and volume
elements that have the COMPOSITE property. The existing methods are used
for the remaining nodes, meaning that a mixed structure of standard materials
(steel, aluminum, etc.) and laminates can be analyzed in a single computation
run.
For laminates, a damage analysis is performed for the top and the bottom of
every layer. In this case, in contrast to standard materials, the stress at the node
is not averaged from the surrounding elements, but instead element node
stresses, or element stresses extrapolated from nodes are analyzed directly so
that erratic changes in the fiber orientation from one element to the next can be
taken into consideration correctly.
Shell and volume elements that have the COMPOSITE property are currently
supported from ABAQUS inp and odb files. LAMINATES results can be
exported for the tops and bottoms of every layer and for every stress
component into an odb file and subsequently be visualized in the ABAQUS
viewer or META. As an alternative, the FEMFAT visualizer can also be
used directly. The result (damage, stress amplitude, mean stress, S/N curve,
etc.) for every individual layer and every stress component can be visualized
separately as can the critical result for all layers and/or stress components.
The analysis group must contain both the nodes to be assessed and the
associated shell or volume elements that have the COMPOSITE property. In
the group menu, it is possible to create groups based on the element type,
whereby laminate shell or volume elements can now be selected as the element
type.
A laminate analysis requires static (tensile and compressive strength) and
cyclical material data (S/N curves) for loads longitudinal and perpendicular to
the fibers as well as shear forces in the laminate plane. The ffd data sets 218
and 223 contain the data for longitudinal and shear loads, while data set 254
contains the data for perpendicular stress. The S/N curves are defined by the
parameters endurance limit, slope and endurance cycle limit. Because an
endurance limit generally cannot be observed for laminates, it is recommended
that for a standard number of load cycles (e.g. 2 million), the associated stress
amplitude limit be specified and the analysis be performed with the “MINER
Elementary” setting.
Furthermore, there is a new material data set, 255, that contains the parameters
for the failure curve according to Puck (also see VDI 2014 or Schürmann
“Konstruieren mit Faser-Kunststoff-Verbunden” (Designing with Fiber/Plastic
Composites)).
As of FEMFAT 5.2, it is also possible to assess failure due to delamination.
New This requires a modeling of the sites which are of interest using volume
elements (generally 8-node hexahedrons) which are able to deliver stress
components perpendicular to the laminate plane. When the “Consider
delamination (for volume elements)“ button is enabled (see Figure 40 –
Influence factors data form – LAMINATES), analysis is performed of both

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the stress components in the laminate plane as well as of those perpendicular to

it. When the button is disabled, only the stress components in the laminate
plane are analyzed.
Analysis of the delamination requires additional material parameters, namely
static and cyclical parameters for tensile loading and interlaminate shear
loading perpendicular to the laminate plane. These can be stored in the new ffd
records 256 and 257. The 3D parameters of Puck’s failure curve can also be
stored in material record 255 in addition to the 2D parameters.
A laminate material must be set to the material class “Continuous fiber-
reinforced plastics”.
It is possible to assign a selected material to every layer. The assignment is
New carried out using a table on the LAMINATES tab. The table shows all the
materials that were imported from the FEM entity file and are contained in
shell/solid sections with a composite property. Each material is listed exactly
once here. It is therefore possible to assign one FEMFAT laminate material
(which was imported from an FFD file, for example) to each one of these
materials. Furthermore, it is possible to assign a FEMFAT material to all
FEM entity materials by means of a single click. This new table replaces the
node-by-node material assignment in the Node Characteristics dialog (when
the LAMINATES module is enabled).
The analysis method is a version of the “Critical Component in Critical Plane”
method that has been adapted for laminates and which takes both fiber
breakage and intermediate fiber breakage into account. Furthermore,
delamination can be taken into account when solid models are used. The failure
curve according to Puck for intermediate fiber breakage is used to limit the
Haigh diagram. The stress vector which generally changes over time, is
projected in the cutting plane perpendicularly to the laminate plane and parallel
to the fiber direction onto different specified directions. For these, rainflow
counting and damage analyses are then performed. The Haigh diagrams and
S/N curves are interpolated between tension/compression and shear forces in
dependence on the polar angle corresponding to the respective direction (0
degrees represents tension/compression, 90 degrees represents shear). The
direction with the greatest damage is considered to be critical for failure. The
number of intermediate directions in a quadrant of the σ2-τ21- diagram can be
specified (the default setting is 2).
The approach used for the analysis of the delamination is analogous. In this
case, the cutting plane considered additionally lies in the laminate plane (i.e.
the cutting-plane normal vector faces outwards from the laminate plane). The
stress vector is projected in directions which, on the one hand, lie between the
σ3 and τ31 direction, and on the other hand, between the σ3 and τ32 direction. A
damage analysis is performed for each of these directions. Consequently,
correspondingly longer analysis times must be expected. The same
specification as for the intermediate fiber breakage in a 2D case is used here for
the number of intermediate directions.

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Furthermore, the reduction of the limit boundary stress for intermediate fiber
breakage or delamination is also considered when the normal stress in the
direction of the fibers exceeds a given value. However, in FEMFAT, this
effect is not calculated in on the loading capacity side, but rather on the load
side so that time-variable boundary stresses can be taken into consideration.
The following influences can be considered in LAMINATES:
- Mean stress influence on fatigue limit and slope / cycle limit
- Haigh diagram construction using the standard FEMFAT 4.1
method
- Alternative: Specification of a user-defined Haigh diagram for
σ1 and τ21. The Haigh diagrams for the other stress components
are derived by means of suitable scaling of the specified Haigh
diagrams.
- General surface treatment factor for all layers
- Statistical influence
Caution: The general surface treatment factor operates on all layers!
Generally speaking, a laminate analysis takes longer than a standard analysis
because, for one thing, more layers and stress components must be analyzed,
and for another, nodes must be calculated several times due to the use of non-
averaged stresses. The following options are available for accelerating the
analysis:
- Analysis filter
- Parallelized analysis
- Reduction, or even no calculation of the intermediate directions
Caution: Currently, it is not possible to combine laminate results using the
Result Manager!

2.7 Strain gage information - STRAIN COMP

For basic information regarding DMS information please read the BASIC
manual. Here, only the differences between BASIC and STRAIN will be
explained. Details on modeling and analysis background information can be
found in the separate STRAIN manual.

2.7.1 Signal length

The signal duration can be defined for both the FEM data and the measured
data. All individual events are then distributed equidistantly through time.

Figure 41 - Signal length input

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2.8 Analysis parameters

The options in the following menu are used for adapting the MAX analysis
parameters to the user-defined values. However, because all parameters are
assigned a default value, it is also possible to start analysis without making any
changes in this data-entry window.
The MAX analysis parameters have a crucial influence on the analysis
duration and on the quality of the final results.

Figure 42 – Analysis parameters data form

2.8.1 Analysis target

How it’s The desired result of the analysis must first be defined here. The following
done options are available:
• Damage
• Endurance Safety Factor
• Static Safety Factor
• Stress/strain comparison
• Degree of multiaxiality
When the program is started, the "Miner modified" damage analysis is
enabled by default.

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2.8.1.1 Damage
For more information on the damage analysis in FEMFAT max please read
the BASIC manual.

2.8.1.2 Endurance Safety Factor

For basic information regarding the endurance limit safety factor please read
the BASIC manual.
In contrast to BASIC, where the amplitude and mean stresses have to be
specified directly by the user, FEMFAT max is characterized by the fact
that they first have to be determined on the basis of the specified stress history.
The procedure is as follows:
The local equivalent stress history is analyzed. This history depends on the
specified equivalent stress; see Chapter 2.8.2.1 Stress selection. If the critical
cutting plane method is applied, the equivalent stress history will also depend
on the spatial position of the analyzed cutting plane. The equivalent stress
history's maximum and minimum values are determined in order to determine
the failure-relevant load cycle. Furthermore, this information is used to
calculate an amplitude and mean stress that is then used to calculate an
endurance limit safety factor (like with FEMFAT basic).

2.8.1.3 Static Safety Factor

For basic information regarding static overload safety factor analysis using the
FEMFAT break module, please read the BASIC manual.
In BREAK for MAX, a separate analysis of the static safety factor is
performed at every node for all times analogously to BASIC. At the currently
analyzed node, the point in time with the lowest safety factor is considered
critical and the associated results are written to the dma and pro files.
Two failure criteria are available for selection:
• Static safety factor for ultimate strength
• Static safety factor for yield strength

2.8.1.4 Stress/Strain Comparison

Only a STRAIN COMP analysis is performed here. See the FEMFAT
strain user manual for details.

2.8.1.5 Degree of multiaxiality

Calculation of the degree of multiaxiality is nothing more than the concept
(method 2) mentioned below for cutting plane filtering (chapter 2.8.4.3.3
Method 2):
The complete stress history in stress space (references: C.C. Chu, F.A. Conle,
A. Hübner, Dearborn, USA; VDI Reports 1283, 1996 (VDI – Verein Deutsche
Ingenieure – "Society of German Engineers") is considered. In the case of a

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planar stress history (σxx, σyy and σxy ), a three-dimensional stress space is
generated.
If m is the number of entries in each load history then there are m points in this
three-dimensional stress space.

Figure 43 - Practically uniaxial Figure 44 – Heavily multiaxial

stress distribution stress distribution

An equivalent ellipsoid, which can be derived from the stress space point
cloud, is used to define the degree of multiaxiality. The ratio of axes lengths of
this ellipsoid is a measure of the degree of multiaxiality of the stress history.
The shape of this point cloud is also characteristic of the multiaxiality.

The real state is located somewhere between the following two extremes:
Shape of the point cloud Ratio of axes
Stress distribution
in stress space lengths

Line (Figure 43) uniaxial stress distribution 0.0

Sphere (Figure 44) extremely multiaxial 1.0

If a degree of multiaxiality of –1 is sent to the *.dma file, this node was not
analyzed.
Overview of degree of multiaxiality m
Value of degree of multiaxiality
Meaning
m
m = +1 Extreme multiaxial loading
+1 > m > 0 Multiaxial loading
m = 0 Pure uniaxial loading
m =-1 Node not analyzed

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2.8.2 Global parameters

This window has no effect on the degree of multiaxiality analysis result.

Figure 45 – "Global parameters" data-input screen

2.8.2.1 Stress selection

Here, the equivalent stress analysis method for damage or endurance limit
safety factor analysis can be selected.
The following methods are currently available:
• Automatic
• Normal Stress in Critical Cutting Plane
• Material Characteristic Shear Stress
• Equivalent Stress in Critical Plane
• Nokleby Criterion in Critical Plane
• Critical Component in Critical Plane
• Critical Component reduced in Critical Plane
• Signed Mises stress 1
(sign from max. principal normal stress)
• Signed Mises stress 2
(sign from hydrostatic stress)
• Max./min. principal stress
• Mod. Equivalent Stress in Critical Plane
• Scaled Normal Stress in Critical Plane

The three classical equivalent stresses (signed Mises stress 1 and 2, and
max./min. principal normal stress) are not cutting plane-specific and therefore
cannot be selected with activated fiber orientation influence (see Section
2.6.1.7). However, all other equivalent stresses are available.

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The selected method determines which equivalent stress is used in FEMFAT

max.
The following steps are performed:
• ChannelMAX: Superposition of the individual stress components
at every point in time (in TransMAX, the stresses for every point
in time are already available directly from the FE results).
• Transformation of the stress tensor into the selected cutting planes
at each point in time (Except for Mises and principal normal stress)
• Generation of equivalent stress for the selected cutting planes
• Rainflow classification of the equivalent stress history
• Computation of all influence factors and the component S/N curve
• Fatigue failure safety or damage analysis for every cutting plane
• Selecting the critical cutting plane: This is the plane where the
minimum endurance limit safety factor and the maximum damage is
found.
• Result output for critical cutting plane.
The equivalent stresses are formed for the respective cutting planes from the
normal stress σN and the shear stresses τx,τy. In order to evaluate the influence
of shear stresses with tensile/compression S/N curves, shear stresses are
multiplied by the factor (σW,ZD/τW,T) for most equivalent stresses, i.e. the ratio
of tension/compression to alternating torsional strength.

2.8.2.1.1 Automatically
The program branches automatically based on the material assigned to the
current node to be analyzed:
• Gray cast iron:
Assessment using Normal Stress in Critical Plane
• all other materials:
Assessment using Scaled Normal Stress in Critical Plane

2.8.2.1.2 Normal stress in critical cutting plane

This method is recommended for very brittle materials.

σ VERGLEICH = σ N

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2.8.2.1.3 Material characteristic shear stress

This method is recommended for very ductile materials.

• 2-axial:

σ 
σ VERGLEICH =  W ,ZD  ⋅ τ x
 τ W ,T 

• 3-axial:

 σ W ,ZD 
σ VERGLEICH = sign(τ x ) ⋅   ⋅ τ x2 + τ y2

 τ W ,T 

For non-proportional loading, this can result in non-physical discontinuities in

the equivalent stress history because of the sign. The Scaled Normal Stress in
Critical Plane method is recommended instead.

2.8.2.1.4 Equivalent stress in critical plane

This method is recommended for materials that are neither very brittle nor
very ductile.

• 2-axial:
2
σ 
σ comparison = sign (σ N ) ⋅ σ N 2
+  W , ZD  ⋅ τ x
2

 τ W ,T 

• 3-axial:
2

σ comparison = sign (σ N ) ⋅ σ N 2 σ 
(
+  W , ZD  ⋅ τ x + τ y
2 2
)
 τ W ,T 

The sign is required for the subsequent rainflow classification and is adopted
from the normal stress. However, when dealing with large pre-stressing, this
can lead to unphysical discontinuities and subsequently to unrealistically large
stress amplitudes, such as represented in the following figure:

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Figure 46 – Normal, shear and equivalent stress

The Scaled Normal Stress in Critical Plane method is recommenced instead

if such discontinuities occur.

2.8.2.1.5 Nokleby Criterion in Critical Plane

A scaling factor has been added to this criterion sourced from the literature in
order to obtain the correct magnitude of the stress vector.
• 2-axial:
with a denominator ≥ 10 -10:

2
  σ W , ZD  σ 
σ N + τ x ⋅   ⋅ σ N 2 + τ x 2 ⋅  W , ZD 
 τ 
  τ W ,T   W ,T 
σ comparison =
σ 
σ N + τ x ⋅  W , ZD 
 τ W ,T 

with a denominator < 10 -10:

σ comparison = 0

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• 3-axial:
with a denominator ≥ 10 -10:

2
  σ W , ZD 
σ N + (τ x + τ y ) ⋅  (
 ⋅ σ N 2 + τ x 2 + τ y 2
 ) σ 
⋅  W , ZD 
  τ W ,T   τ W ,T 
σ comparison = 
( ) σ
σ N + τ x + τ y ⋅  W , ZD 

 τ W ,T 

with a denominator < 10 -10:

σ comparison = 0

2.8.2.1.6 Critical component in critical plane

This is the so-called "Critical Component in Critical Plane" method, which
was developed at the Technologie Zentrum Steyr (Steyr Technology Center).
Besides a critical cutting plane, a critical stress component is also searched for.
Analysis duration is therefore several times longer than when using other
equivalent stresses. Thus, using this method generally only small regions of a
FEM model can be analyzed; otherwise the analysis time would be unbearably
long. However, this method offers substantial advantages:
• Both normal and shear stress components, including all combinations, are
considered and subjected to a damage analysis. This is a crucial advantage
above all for ductile materials.
• The equivalent stress history (corresponds to the stress component history)
is always constant. No unphysical leaps can occur as with some other
equivalent stresses.
• Depending on load, a correct Haigh diagram is now applied (asymmetrical
for tension/compression, symmetrical for shear, interpolated Haigh diagram
for combined load cases).
• The interpolation curve between tension/compression and shear is adjusted
to test results.
• It is also possible to specify an S/N curve as an option. Then, the slope and
New endurance cycle limit between tension/compression and shear are also
interpolated.

2.8.2.1.7 Critical component reduced in critical plane

In order to speed up the computation process, a further variant of the "Critical
Component in Critical Plane " method is provided, by which normal and

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shear stress in the cutting plane are separately evaluated, with the exception of
components resulting from a combination of the two. In the plane strain state,
only 2 computations are therefore performed, one for the normal and one for
the stress component, representing a substantial reduction in contrast to up to
18 computations (at 10° intervals) previously required using the original
method. The result is the greater of the two damages (or the smaller safety
factor).

2.8.2.1.8 Signed Mises stress 1

(Sign from max. principal normal stress)
If you require rapid identification of critical locations and less interested in a
high-quality absolute damage forecast, adoption of a signed Mises stress is
recommended for ductile materials. The loop across all cutting planes is no
longer needed, which leads to a substantial increase in the speed of the
computation process. The sign is necessary in order to identify stress cycles by
means of a rainflow counting algorithm. However, unphysical discontinuities
in the stress history may occur for heavily non-proportional loading and thus to
excessive stress amplitudes. Nevertheless, the result is almost always
conservative. Two variants are available for the sign: Sign of the max. principal
normal stress or sign of the hydrostatic stress. Which variant is most favorable
depends in principle on the progression of the local stress conditions and must
be decided empirically.

2.8.2.1.9 Signed Mises stress 2

(sign from hydrostatic stress)
See description of previous stress "Signed Mises Stress 1 (sign of max.
principal stress)".

2.8.2.1.10 Max./min. principal stress

If you require rapid identification of critical locations and less interested in a
high-quality absolute damage forecast, adoption of the maximum principal
normal stress is recommended for brittle materials. The loop across all cutting
planes is no longer needed, which leads to a substantial increase in the speed of
the computation process. At all times, the greatest principal normal stress value
is adopted, with the corresponding sign. The sign is necessary in order to
identify stress cycles by means of a rainflow counting algorithm. However,
unphysical discontinuities in the stress history may occur for heavily non-
proportional loading and thus to excessive stress amplitudes. Nevertheless, the
result is almost always conservative.

2.8.2.1.11 Mod. equivalent stress in critical plane

This equivalent stress is also available in FEMFAT basic, see there.

2.8.2.1.12 Scaled normal stress in critical plane

Using this option can solve the problem of signs for some equivalent stresses.
Procedure is as follows:

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• Calculation of principal normal stresses σ1 > σ2 > σ3 at every point in

time. In ChannelMAX the existing superimposed stress states are
used.
• Calculation of the ratio of minimum/maximum principal normal stress
at all times:
σ3
V =
σ 1 for |σ | > |σ |
1 3

σ1
V =
σ 3 for |σ | > |σ |
3 1

V is a value between –1 and +1 has the following meanings:

• V = -1: dominant shear load
• V = 0: dominant tensile/compressive load
• V = +1: hydrostatic stress state
• The stress tensor at all times is now scaled as a function of V. The
scaling factor is:
f = 1 + (1 − k )V
σW
k=
τW
So the stress remains unaltered for tension/compression. For shear it is
scaled up by the factor k, in order to model the damaging effect of
shear. For the hydrostatic stress state, f is linearly extrapolated. This
really makes sense because the reduction of the stress state associated
with it is compliant with the maximum shear strain energy criterion.
• The critical cutting plane method is subsequently employed. The
rainflow classification of the normal stress with subsequent damage
analysis using the influence parameter concept is performed in the
cutting plane.

2.8.2.2 Survival probability

Survival probability see BASIC manual.

2.8.2.3 Rainflow classification

2.8.2.3.1 Number of Rainflow classes

The equivalent stress histories in the cutting plane are subjected to a rainflow
classification in order to make the damage analysis loading information
available. This means that the resultant loading is saved in a square
amplitude/mean stress matrix.
When the program is started, the number of rainflow classes is set to 64 by
default , i.e., the rainflow matrix has 64x64 elements.

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2.8.2.3.2 Rainflow counting method

Two types of rainflow counting are available: FEMFAT 5.0 (standard setting)
and FEMFAT 5.1. The difference between these two methods lies in the
handling of open hysteresis loops (residuum).
The FEMFAT 5.0 method performs a separate damage analysis for the
residuum and includes this result in the total damage using a weighting factor
(see Chapter 2.8.2.3.3).
In contrast to this, the FEMFAT 5.1 method assumes a periodic history so that
all hysteresis loops are closed and thereby the residuum disappears. This
method yields the same value for the total damage of a periodic load as for an
individual period multiplied by the number of repetitions. This is not the case
using Method 5.0 because of the residuum and because the number of closed
or open hysteresis loops and in consequence the damage in general do not scale
exactly with the number of repetitions.
Caution: The method of FEMFAT 5.1 is the default setting as of FEMFAT
New 5.2. This can lead to changes in the results in comparison to previous versions.

2.8.2.3.3 Damage residuum factor

When the load-time-information in a cutting plane is rainflow-classified with
the FEMFAT 5.0 method, a residuum remains, i.e. open hysteresis loops. All
open hysteresis are artificially closed and subsequently subjected to further
damage analysis. The result is a damage value which is then multiplied with
the damage residuum factor and added to the "real" damage value from closed
hystereses. Allowable and sensible values for this factor lie between 0.0 and
1.0.
When the program starts, the damage residuum factor is set to the default value
of 0.50 (acc. to ASTM standard, see also Haibach, Operational Strength, 2nd
edition, page 375). This function is not available with the FEMFAT 5.1
rainflow counting method (see Chapter 2.8.2.3.2).

Figure 47 - Determination of all open hystereses in the load-time history

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Figure 48 - Mirroring of all open hystereses

2.8.2.3.4 Amplitude limit for class filter

This entry field is used to specify a limit for the amplitude stress, with this in
turn belonging to a rainflow amplitude class. All rainflow matrix entries in
classes below the defined amplitude class are set as 0 and therefore not taken
into account in the succeeding damage calculation ("omission").

This limit is naturally effective only for values greater than 0.

2.8.2.3.5 High resolution

The default setting for the High Resolution check box is disabled. In this case,
the numerically greatest value of the equivalent stress is used for the
determination of the class width. The mean stress level zero is always placed at
the center of the rainflow matrix, i.e. by default at class 32. The loss of
accuracy due to the classification is greater when the check box is disabled,
however, the computation is faster due to the lower level of inclusion in the
rainflow matrix.
When the check box is enabled, the greatest oscillation width is used to
determine the class width. This increases the accuracy, but the computation can
take longer due to the generally higher level of inclusion in the rainflow matrix.

2.8.3 Analysis filter

As already described in FEMFAT basic, MAX also works with stress-
dependent filters, in order to reduce analysis times.
Normally, detailed analysis results are only of interest for the highly-stressed
regions of the model. Here, there are three possibilities for limiting the node
result data in these regions:
1) The number of nodes in the active analysis group should be kept as small
as possible.
In this case the analysis time is kept to a minimum. The practical difficulty
here is that at the time of group creation (in the respective pre-processor or
in the Groups menu item) the highly stressed areas are not known or can
only be collected to groups with difficulty. Those nodes that do not belong

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to the analysis group are graphically represented by "white areas" in the

postprocessor.

2) Specifying a relative stress limit

3) Specifying an absolute stress limit

When the “Advanced” check box is enabled during filtering, it is possible to

specify a separate filter value for base material, SPOT, WELD and
LAMINATES analyses.

Figure 49 – "Analysis filter" data form

2.8.3.1 Relative stress limit

The default definition is a relative stress limit of 40%. This means that nodes
with a maximum stress amplitude smaller than 40% of the local material
fatigue strength and a mean stress smaller than 40% of the tensile strength will
not be analyzed. The corresponding results for such nodes will be allocated
dummy values in the output file.
If you change the analysis filter from "Relative stress limit" to "Absolute stress
limit," the filter limit will be set to zero by default. If you change the analysis
filter from "Absolute stress limit" back to "Relative stress limit," the filter limit
will be set to 40% by default.
The maximum stress amplitudes are determined for each channel in
ChannelMAX as specified below:

• Calculation of the largest occurring load amplitude for each channel.

• An associated stress amplitude for the analyzed nodes, which is
superimposed on all channels, is calculated for each of these load
amplitudes.

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• Calculation of corresponding equivalent von Mises stress for each channel.

• Determining the corresponding mean equivalent stress for each channel.

Filter criteria:
σa Maximum stress amplitude at the node for a channel
σm Corresponding mean stress at the node
σW,ZD Material alternating stress limit at node
Rm Tensile strength
Rm,D Compressive strength
Slim Relative stress limit in percent

A node is processed if the following is true for at least one channel:

σ W , ZD ⋅ S lim Rm ⋅ S lim R ⋅S
σa ≥ σm ≥ σ m ≤ − m , D lim
100 or 100 or 100

Maximum stress amplitudes with the corresponding mean stresses are also
determined locally on the node for TransMAX. The maximum and minimum
values of the principal normal stresses are combined with each other for this
purpose. The filter criteria are the same as in ChannelMAX.

2.8.3.2 Absolute stress limit

An absolute stress limit is defined in order to skip analysis of nodes with low
stresses. In the case of multiaxial damage forecasts, the above described
procedure is carried out in order to determine the maximum stress amplitudes
at the node.
Filter criteria:
σa Maximum stress amplitude at node
σm Corresponding mean stress at the node
σlim absolute stress limit

A node is processed if the following is true for at least one channel:

≥ or ≥ or ≤− ,
, ,

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2.8.3.3 Analysis filter for WELD nodes

For WELD nodes, activating the “Advanced” check box makes it possible to
configure filter settings separately from the base material and from SPOT
nodes. More detailed information regarding the relative/absolute analysis filter
can be found in the BASIC manual.
In order to assess whether a node is filtered or not an estimate of the maximum
occurring notch stress is carried out for every weld element. First, the
maximum notch factor on the top and bottom of the shell is estimated (for
details, please see the BASIC manual).
Subsequently, the Mises equivalent notch stress amplitude and the mean notch
stress for the shell top and bottom are formed from the maximum and
minimum values of the (in ChannelMAX superimposed) element stress
components (normal stress perpendicular and parallel to the weld, as well as
shear stress), taking the maximum notch factor into consideration. Beside the v.
Mises stress the principal normal stresses are also determined here. The largest
absolute principal normal stress gives the sign for the v. Mises mean stress.
Subsequent filtering is based on the v. Mises equivalent stresses

2.8.3.4 Analysis filter for SPOT nodes

For SPOT nodes, activating the “Advanced” check box makes it possible to
configure filter settings separately from the base material and from WELD
nodes. For general information regarding the analysis filter for SPOT please
read the BASIC manual.

In ChannelMAX, filtering is carried out for every channel. If one of the

channels is not filtered the analysis is performed for the current joint. To
determine the amplitude or the mean stress, the stress components are
superimposed on the times of the maximum and minimum of the load history
of the current channel, and the amplitude and mean equivalent stresses are
calculated from these superimposed stresses. (Either signed Mises stress or
radial normal stress, depending on the setting.) In TransMAX, the points in
time at which the maximum and minimum equivalent stress values occur are
used.
σ − σ min σ + σ min
σ a = max σ m = max
2 2

2.8.4 Cutting Plane Parameters

This window has no effect on the degree of multiaxiality analysis target!

The options in this menu can be utilized to adjust the MAX cutting plane
parameters to user-defined values. Nevertheless, because every parameter is

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assigned a pre-defined value, it is also possible to start analysis without

carrying out any modifications in this area.
The MAX cutting plane parameters have an important influence on the
analysis duration and on the quality of the final result.

Figure 50 – "MAX analysis parameters" data-entry screen

2.8.4.1 Cutting plane/node filter

• 2D stresses, surface nodes
This option is activated by default and should always be used if a
plane stress state at the surface can be assumed, which is the case for
most applications.
• 3D stresses, surface nodes
If stress components normal to the component surface occur (e.g. due
to external pressures on the surface), i.e. a 3D stress state, this option
must be activated.
• 3D stresses, all nodes
If cracks can occur in the component interior, for instance because the
surface is hardened, this option should be activated. A tri-axial stress
state is always assumed. Analysis time is correspondingly longer.

2.8.4.2 Angle between cutting planes

When the program is started the angle between cutting planes is at the default
value of 10° (this means 18 different cutting planes for a 2D stress analysis).
As mentioned above, a finite number of cutting planes is considered in order to
calculate the interactions between the various dynamic load histories. A
FEMFAT max operational strength analysis is nearly always limited to the
surface of the FEM model, which is where the cracks formation usually
commences. In the surface region, the stress state is two-dimensional, as far as

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no surface pressures are present. Thus, all cutting planes contain the vector
normal to the surface of the model. The angle between these is measured in the
surface of the model.

Figure 51 - Cutting planes on a 3D model

Angle between the cutting Expected result Expected analysis

planes precision duration
small good long
large poor short

2.8.4.3 Filtering method

The multiaxial operational strength analysis is generally calculation-intensive,
in particular if large FEM models are to be analyzed. In order to decrease
calculation time, it is possible to automatically skip those cutting planes for
which it can be assumed that they will not influence the final fatigue result.
FEMFAT max provides three methods for cutting plane filtering:
• None
• Method 1
• Method 2

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If the fiber orientation is taken into consideration, the material parameters can
be different for each cutting plane. It is therefore not possible in this case to
carry out cutting plane filtering based solely on stresses. The reciprocal of the
safety factor is therefore utilized for cutting plane filtering if the fiber
orientation influence is activated. Use of method 2 is not permissible if the fiber
orientation influence is active.

Figure 52 - Cutting plane filter method taking fiber orientation into consideration

2.8.4.3.1 None
No filter is active, so all cutting planes will be applied.

2.8.4.3.2 Method 1
In the case of ChannelMAX, the maximum equivalent stresses of all
channels which were derived from a projection of the FEM stress tensors in the
cutting plane are used to select the cutting planes of interest. The calculation
method for equivalent stresses is described in Chapter 2.8.2.1.
Only those cutting planes in which the equivalent stress exceeds a certain
percentage of the maximum equivalent stress of all cutting planes are used for
damage analysis (see Chapters 2.8.4.4 Channel stress filter limit method 1 and
2.8.4.5 Upper stress filter limit Method 1).
Equivalent stress formation is for each channel individually and in addition for
the superpositioning of all channels.
In the case of TransMAX , the selection of the cutting planes for the
individual time steps is made in the same way as for the individual channels in
the case of ChannelMAX. A consideration of superimposed stresses does
not take place.

2.8.4.3.3 Method 2
The filter method 2 algorithm is based on the analysis of the degree of
multiaxiality (see the associated Chapter 2.8.4.65). As is explained in detail
there, the entire stress history is considered in the stress space and an
equivalent ellipsoid is derived from the resulting point cloud.

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The ratio of axes lengths of this ellipsoid is a measure of the degree of

multiaxiality of the stress history. The position of the critical plane is acquired
from the stress tensor, which is embodied by the maximum main axis of this
ellipsoid. Further planes are selected for method 2 in accordance with the lower
and upper filter limit (see corresponding Chapters 2.8.4.6 and 2.8.4.7).

Method 2 should not be used concurrently with the characteristic material

shear stress!

2.8.4.4 Channel stress filter limit method 1

As previously mentioned, the greatest equivalent stresses in relation to time of
all channels are calculated for all cutting planes in the case of
ChannelMAX.
The maximum value of the equivalent stress designates the critical plane which
is automatically selected. Further planes are selected in accordance with the
corresponding channel filter limits for Method 1 as follows.
σEQUIVAL Equivalent stress of a specific channel and cutting plane
σMAX. EQUIVAL Maximum value of the equivalent stress of a specific
channel
λREL. LIMIT Relative channel stress filter limit in percent.
When the program starts, the channel stress filter limit
for Method 1 is set to the default value of 99.9%.
When using the "critical component" method the limit
is reduced to 98%.
σ MAX . EQUIVAL ⋅ λ REL . LIMIT
σEQUIVAL LIMIT = 100

A cutting plane must be considered if

σ EQUIVAL > σ EQUIVAL LIMIT

Please note the example at the end of the next chapter.

In the case of TransMAX, this filter limit setting affects the stress data of a
time step instead of a channel in a completely analogous manner.

2.8.4.5 Upper stress filter limit Method 1

As previously mentioned, the maximum equivalent stresses of all channels in
each cutting plane are additionally superpositioned in order to cover the
possible case of simultaneously occurring stress peaks.

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Only the cutting planes in which the upper equivalent stress does not exceed a
given percentage of the maximum value are selected for damage analysis.
σ MAX . EQUIVAL ⋅ λ REL . LIMIT

σEQUIVAL LIMIT = 100

When the program starts, the upper stress filter limit for Method 1 is set to the
default value of 99.9 %. When using the "critical component" method the limit
is reduced to 98%.
A cutting plane is considered if

σ EQUIVAL > σ EQUIVAL LIMIT

This setting has no effect on TransMAX.

We will use the following example to explain filter Method 1:

Illustrative example:
• Three channels
• Angle between the cutting planes = 10 degrees
• Channel stress filter limit for Method 1 = 95 %
• Upper stress filter limit for Method 1 = 98 %
• Selected cutting planes for the subsequent analysis steps

Angle [°] Channel 1 Channel 2 Channel 3 Σ Sum

σEQUIVA Select. σEQUIVA Select. σEQUIVA Select. σEQUIVA Select.
(cutting plane)
L plane L plane L plane L plane
*0.0 0.42 0.13 0.06 0 0.61
10.0 0.29 0.16 0.04 0.49
20.0 0.16 0.19 0.02 0.37
30.0 0.03 0.21 0.00 0.24
40.0 0.11 0.21 0.02 0.34
*50.0 0.24 0.23 50 0.03 0.50
*60.0 0.36 0.23 60 0.04 0.63
70.0 0.48 0.21 0.03 0.72
80.0 0.58 0.21 0.02 0.81
90.0 0.66 0.19 0.01 0.86

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100.0 0.72 0.16 0.00 0.88

*110.0 0.76 110 0.13 0.01 0.90 110
*120.0 0.78 120 0.10 0.03 0.91 120
*130.0 0.77 130 0.06 0.03 0.86
*140.0 0.75 140 0.02 0.02 0.79
150.0 0.69 0.02 0.01 0.72
160.0 0.62 0.06 0.04 0.72
170.0 0.52 0.10 0.04 0.66

σ MAX. 0.78 0.23 0.06 0.91

σ REL. LIMIT 95 % 95 % 95 % 98 %
σ EQUIVAL 0.74 0.22 0.05 0.89

A cutting plane is selected for further analysis steps if its angle in column 1 is
marked with "*".

Channel or upper stress Expected damage final Expected analysis

filter limit for Method 1 result precision duration
low good high
high poor low

2.8.4.6 Lower filter limit Method 2

The position of the probable most critical plane results from, as mentioned
above, the stress tensor which is embodied by the largest axis of the equivalent
ellipsoid in stress space. Further planes are selected for Method 2 in
accordance with the lower and upper filter limit around the critical plane.
When the program starts, the lower filter limit for Method 2 is set to the default
value of 1 %.
This menu item can be used to modify the lower filter limit. The effects of both
limits are described in the next section.

2.8.4.7 Upper filter limit Method 2

This menu item can be used to modify the upper filter limit.
When the program starts, the upper filter limit for Method 2 is set to the default
value of 30 %.

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As mentioned above the axes ratio of the equivalent ellipsoid, which is derived
from the stress space point cloud, is a measure of the degree of multiaxiality of
the stress history.
V Axes ratio of the equivalent ellipsoid
λ LIMIT 2 U Lower filter limit for Method 2 (in percent)
λ LIMIT 2 O Upper filter limit for Method 2 (in percent)
N TOT Total possible number of cutting planes
180
NTOT =
angle _ between _ cutting _ planes
for a plane stress state
N Number of cutting planes selected for the analysis steps

Filter criterion Number N of cutting planes

N =1
V < λ LIMIT 2 U
Only the most critical cutting planes

N TOT − 1
N = 1+ ⋅ (V − λ LIMIT 2 U )
λ LIMIT 2 O − λ LIMIT 2 U
λ LIMIT 2 U < V < λ LIMIT 2 O
All selected cutting planes have the most
critical plane at the center.

N = N TOT
V > λ LIMIT 2 O
All cutting planes

In Figure 53 the filter criteria are clearly summarized:

N TOT

λ LIMIT 2 U λ LIMIT 2 O V
Figure 53 – Filter method 2

Lower/Upper filter limits Expected damage final Expected analysis

for Method 2 result precision duration
low good high

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high poor low

2.8.5 Result group

See BASIC manual.

2.8.6 Result visualization

See BASIC manual.

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2.9 Scratch settings

The creation of the scratch files is the first “work step” in a MAX analysis and
therefore, the scratch files can be dependent both on certain analysis settings
(e.g. the analysis group selected, the WELD stress correction factor, etc) and
on the FEMFAT version used. Therefore, in most cases, the use of scratch
files created using an older FEMFAT version will not be possible or will lead
to errors.

2.9.1 ChannelMAX

Figure 54 – MAX scratching - ChannelMAX

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2.9.1.1 Creating the ChannelMAX scratch files

2.9.1.1.1 Automatic stress correction for weld seams

If this influence is activated the stress at a constant distance from the weld is
determined in FEMFAT weld analyses of the weld. In this way, the
influence of the element size on the notch stress is reduced.
A change in the default thickness factor of 1.0, i.e. the stress is extrapolated to
a distance of 1 x plate thickness from the central plate plane of the shell
element, is not recommended.
"Automatic Weld Stress Correction" must be activated before the scratch
files required for FEMFAT max are created.
If the "Automatic Weld Stress Correction" is activated after creating the
scratch files, "Automatic Weld Stress Correction" is activated but will not
have any influence!
If, on the other hand, the scratch files were created with the "Automatic Weld
Stress Correction" activated and this influence is later deactivated, analysis
will still be performed with "Automatic Weld Stress Correction", even
though this influence is now apparently deactivated.
So the influence of "Automatic Weld Stress Correction" in the case of
FEMFAT max refers purely to the creation of the scratch files, because the
stresses to be evaluated are saved with the scratch files. That is, for a WELD
node, the stress components of the determined stress tensor at the assessment
point, projected on to the weld, are already present in the scratch files.
If the scratch files were written with the "Automatic Weld Stress
Correction" influence activated, it is only possible to perform an operational
strength analysis with consideration of this influence.
If, on the other hand, the scratch files were written with the "Automatic Weld
Stress Correction" influence deactivated, it is only possible to perform an
operational strength analysis without consideration of this influence.
One should also note that for WELD nodes (node color 100-109), both the
stress tensors for the base material and the weld information are always
written to the scratch files, irrespective of whether FEMFAT weld is
enabled or not. It is only when reading the scratch files during analysis that the
WELD switch comes into play, determining whether the weld information
(WELD=ON) or the base-material stresses are imported (WELD=OFF).

2.9.1.1.2 Overwriting existing files

If the check box is activated any existing scratch files
are overwritten (default). If the check box is deactivated, the scratch files are
only written for the channels that do not yet have scratch files. With the aid of
input data checking it is possible to determine which channels do not yet have

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scratch files. Finally, the existence of all necessary scratch files is checked
again before analysis commences.

Figure 55 - Check box for overwriting the scratch files

If the channel definition is altered during the same session after the scratch file
is created, e.g. the stress file format, file name, load case number, scratch file
format or sheet thickness factor for the automatic stress correction, the scratch
file name for the affected channels is shown in bold type. If new scratch files
are created again, or an analysis is started without creating the scratch files, the
bold-type, existing files are overwritten, even if the "Overwrite existing files"
check box is deactivated.
In the channel definition table it is also possible to overwrite individual scratch
files with the aid of the right mouse button (see Figure 56).

Figure 56 - Marking a scratch file for overwriting in the table

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The progress bar in Figure 55 is automatically reset depending on the current

status. It only displays 100% if
if all scratch files exist and the analysis can be
carried out correctly.
The missing scratch file names are marked red in the channel definition table
during the input data check.

2.9.1.1.3 Reading stress data and load history

Press "Write" to import the stress data. Progress is displayed as a percentage in
the corresponding box.

2.9.2 TransMAX
2.9.2.1 Creating the scratch files for TransMAX

Figure 57 – Scratch settings – TransMAX

Automatic stress correction for weld evaluation using FEMFAT weld is

also available for TransMAX.

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In analogy to ChannelMAX, also the corrected stresses where written to the

scratch files in TransMAX. Thus, the same rules regarding automatic stress
correction are valid for TransMAX as mentioned above.

2.9.2.2 Stress file settings

New A single scratch file is created for the stress data of the base material. The
default setting is to use the project name with the file extension “.fss” as the
name of the file. However, the user is able to select the name as desired. For
WELD and SPOT, one scratch file is created for each of the six stress
components. These six files all have the same name as the scratch file of the
base material but with different file extensions:
Stress
Stress Extension
components
Normal stress xx *.s00
Shear stress xy *.s01
Normal stress yy *.s02
Shear stress xz *.s03
Shear stress yz *.s04
Normal stress zz *.s05

2.9.2.3 Creating New Scratch Files

Actuating the “Write” button when “Generate/overwrite existing scratch files”
is enabled will start the creation of the files based on the settings made
previously.
Generation progress can be seen in the progress display.
The scratch files are created for the current analysis group. Enlarging the
analysis group after the scratch file has been created leads to errors during
analysis, although it can be reduced in size.

2.9.2.4 Using existing scratch files

It is also possible to utilize existing scratch files. To do so, the selection box
“Generate/overwrite existing scratch files” must be disabled. It is then possible
to open an existing scratch file using the button for file selection. Selection of
the fss file or one of the six s0* files is equally possible here. The entire set of
stress files is always used for the analysis. If all files are present (fss and s00 to
s05), the progress bar is set to 100%. If one or more files are lacking, the
progress bar shows 0% and a new scratch is required.

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The name of the analysis group, the number of nodes and the number of points
in time are shown after successful creation or after selection of an existing
scratch file.

2.9.3 Checking MAX input data

Once the corresponding scratch files have been created, it is advisable to check
the input data before commencing analysis.

2.10 Output

2.10.1 FPS Setting

A description of the output into the FPS (“FEMFAT Permanent Scratch“) file
can be found in the BASIC manual, Chapter 2.10.1.1.
Peculiarities for FEMFAT max:
“Misc.” Output:

Figure 58 - Output menu - FPS Setting - Misc.

Here, output of:

• Normal vector of the critical cutting plane (x, y, z),
• The secondary dendrite arm spacing SDAS,
• The critical load case Min.Max (for safety factor analyses, the
two times at which the equivalent stress history achieves its
maximum and minimum are separated by "." for output. If the
times have more than three decimal places, they are rounded to
three decimal places),
• The critical vector for force-based SPOT assessment
can be selected.

2.10.2 DMA-Column Setting

A description of the settings for output into the dma (“Damage”) file can be
found in the BASIC manual, Chapter 2.10.1.2
Peculiarities for FEMFAT max:

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When calculating the degree of multiaxiality (see Chapter 2.8.1.3), the

following assignments are selected when the Default button is pressed:
Column Assignment
1 Degree of multiaxiality
2 .. 6 empty

2.10.3 Result modification

A description of the output modification for the dma file can be found in the
BASIC manual, Chapter 2.10.1.3

2.10.4 Module-specific outputs

2.10.4.1 MAX

Figure 59 - Output menu - Module specific output MAX

• DETAILED RESULT CSV files

CSV (Comma Separated Values) ASCII files containing the following data
are output for all "output nodes", i.e. nodes in the DETAILED RESULTS
group:

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o Maximum stress values for each channel

(ChannelMAX only)
o Unit stress values for each channel
(ChannelMAX only)
o equivalent stress history
o partial damage history
o total damage history

The output of the ASCII files can be individually controlled via check
buttons. By default, all files will be written.

• Critical load case

ChannelMax:
The critical combination of the specified load cases for the maximum
damaged node is searched for, or the node specified by the user before
commencing analysis in the menu item Analysis parameters – "Results
Visualization at".
The critical load case is defined by the individual load case factors, which
are specified during the FEMFAT analysis and can be exported in the
shape of a NASTRAN LOAD card. This LOAD card is composed of the
load factors and corresponding load case numbers of all load channels.

Three options are available for defining the load case numbers in the file to
be exported:
• importing from the file
• using the FEMFAT load case numbers
• assign numbers increasing from one

The following points should be noted if the load case numbers are imported
from a file:
The NASTRAN Bulk file, with which the unit load cases were analyzed,
must be defined in Load case number from - File in order to allow the
correct load case numbers to be imported.
The number of load case definitions in the definition file must correspond
to the number of channels defined in ChannelMAX. If this is not the
case, the load case number will be assumed as follows:

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1. False subcase definition:

The program ignores the subcase definition and uses the "LOAD=..."
lines only.
2. Too many load definitions:
The load case numbers are allocated according to the labels of the
FEMFAT channels.
3. Too few load definitions:
The missing load case numbers are allocated automatically following
the largest load case number in the input file.
In addition, a file name for the load card output must be defined under
output file before the load cards are generated by clicking on Write.
In order to subsequently analyze the critical load case using NASTRAN,
both of the lines "LOAD=..." and "LOAD..." of the output text file must be
transferred to the original NASTRAN-BULK file. The old load case
definitions must be deleted.
For ChannelMAX analyses it is possible to define load card export
parameters in "Load case Definition". In the default setting the maximum
amplitude factors are exported. Two additional NASTRAN-LOAD cards
are output for this purpose for the two times of maximum and minimum
equivalent stress. The second option provided by the program is to output
the load card for an arbitrary time.

Figure 60 - Definition of the critical load case

TransMAX:
No file names need be defined in TransMAX, because here the times of
both equivalent stress history extremes are only displayed in an
information window when is clicked:

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Figure 61 - Information window, Critical load case TransMAX

2.10.4.2 SPOT
After the damage has been calculated, the spot welds in the entity can be
increased in diameter using their damage values. A more detailed description
can be found in the BASIC manual in Chapter 2.10.4.1.

2.10.4.3 STRAIN
Once the STRAIN COMP analysis is complete a result file is created for
each defined strain gage, containing the stresses and/or strains for all
measurement grids, depending on the choice made, and including Mises
equivalent stresses and/or strains for rosettes. A more detailed description can
be found in the BASIC manual in Chapter 2.10.4.2.

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2.11 Report
A description of the output settings for the pro (protocol) file can be found in
the BASIC manual. Peculiarities for FEMFAT max:

2.11.1 Result output for fiber reinforced plastics

In addition to the previously available output options, further information is
exported to the report file during analysis of short-fiber reinforced plastics
(activation of fiber orientation influence, see Chapter 2.6.1.7). This
information includes the fiber components, principal fiber directions and the
tensile strength in the critical cutting plane at the node.

Structural Node Data

=========================
Node_Label ...................................... 2574N
Node_Color ...................................... 0
Structural_Component ....................... Basic Material
Internal_Specimen_Material_Number ............... 2

Whole number/selected cutting planes: 18, 18

Normal-vector of crit. cutting plane: 0.6427876, 0.7660445, 0.0000000
Portion of fibers (L1, L2, L3): 0.8889925, 0.0741684, 0.0368387
Fiber direction 1 ............. 0.0043794, -0.9868506, -0.1615760
Fiber direction 2 ............. 0.9996432, 0.0000616, 0.0267110
Fiber direction 3 ............. 0.0263363, 0.1616353, -0.9864991
Ultimate tensile strength in the crit. cutting plane (Lv): 79.62
[N/mm2]
Damage (Shell top, 3D) .............................. 6.6623E+00
Stress_Data_and_Component_S/N_Curve
Top: Ampl. class: 29 Mean Class: 1 Damage_Share: 6.6565E+00
Ampl.-Equi.-stress: 34.4 Load-cycle : 999
Endurance stress limit: 15.6 Slope: 1.4200E+01 Endurance cycle
limit: 10000000

Relative Stress Gradient (Shell top, 3D) .. 0.000 [1/mm]

Corresponding Support Number .............. 1.000 [-]
Surface Roughness ......................... 1.0 [mum]
Technological Size of Component ........... 7.5 [mm]
Tempering Cond.(for Temp.Steel only) ...... 106.0 [N/mm2]
Temperature at Node ....................... 20.0 [C]
================================================================
Figure 62 - Extract from the report file for short fiber reinforced plastics

2.11.2 Relative stress limit

For more information see BASIC manual.
Restriction of result data in the report file through filters:
A "Relative Stress Limit" is defined in order to suppress output to the report
file of nodes with low characteristic stresses. However, in the case of
multiaxial analyses a special procedure is necessary in order to determine a
characteristic stress limit. This method works exactly as with the analysis filter;
see Chapter 2.8.3.1 - Relative stress limit.

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2.12 Analyze
See BASIC manual.

2.13 Visualization
2.13.1 Analysis Visualization
A description of the graphical representation of the analysis result, the S/N
curve, the Haigh diagram, and the rainflow matrix can be found in the BASIC
manual, chapters 2.10.3.1 to 2.10.3.4.

2.13.2 MAX visualization

2.13.2.1 History

2.13.2.1.1 Equivalent stress history

For the critical or a selected node or if a DETAILED RESULTS group has
been defined, an equivalent stress history for all analyzed nodes of the
DETAILED RESULTS group can be visualized.

Figure 63 – Dialog window - Equivalent stress history

However, the data stored in the fps file is transferred to a CSV file (comma
separated values) which can then be imported into and edited in a standard
spreadsheet application, for example (DETAILED RESULTS files can be
found in Chapter 2.10.4 - Module-specific outputs).

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2.13.2.1.2 Damage history

If a DETAILED RESULTS group has been defined and a damage analysis
performed, both the total damage history and the partial damage history for all
analyzed nodes of the DETAILED RESULTS group can be visualized.

Figure 64 - Damage history

Example of damage distribution:

Figure 65 – Example of a stress history

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Closed cycles
The damage D of the closed cycle is distributed over time points 2 and 3.

Residue:
The damage R of the residue is distributed over time points 1 and 4.
However, the data stored in the scratch files is transferred to CSV files, which
can then be imported into and edited in a standard spreadsheet application, for
example (DETAILED RESULTS files can be found in Chapter 2.10.4 -
Module-specific outputs).

2.13.2.2 Strain Gage Chart

If a FEMFAT strain analysis has been performed, the strain gage history
can be visualized.

Figure 66 - Visualization of FEMFAT strain analysis results

The respective histories of the stress component in the direction of the strain
gage and for rosettes also the v. Mises equivalent stress and strain will be
displayed.

2.13.2.3 FEMFAT Visualizer

In addition, all analysis results can be viewed directly on the FEM model with
the help of the VISUALIZER. See the FEMFAT Visualizer manual for
details.

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2.14 FEMFAT menus

Through the FEMFAT menu bar you can call up various FEMFAT
functions (details see BASIC manual).

2.15 Result Manager

This module allows FEMFAT results to be scaled and combined, and the
results of several analysis runs to be amalgamated to form a single result
(details see BASIC manual).

2.16 Postprocessing
Details see BASIC manual.

We wish you every success with the design and evaluation of your components
using FEMFAT max.
Your FEMFAT Team
Phone ................. ++43 (0) 7435 501 - 5300
Fax ..................... ++43 (0) 7435 501 - 2300
Email ................. femfat.support.ecs@magna.com
Internet .............. http://www.FEMFAT.com
St. Valentin, December 2015

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