Вы находитесь на странице: 1из 62

SECTION 1 OVERVIEW OF DURABILITY AND FATIGUE LIFE ANALYSIS

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-1

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-2

COURSE OBJECTIVES
Solve durability problems using MSC Fatigue. Students will work through a number of workshop problems in

class with assistance from the instructor


Simple workshop problems designed to introduce basic concepts Apply the basic concepts of fatigue analysis: total life (S-N), crack

initiation (E-N), crack propagation (LEFM), and vibration fatigue. Learn the theoretical background of fatigue and durability analysis Apply knowledge of fatigue and durability analysis to improve product life by avoiding premature fatigue failures. Integrate fatigue analysis with testing.

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-3

COMPANY OVERVIEW
The MSC Software Corporation has been supplying

sophisticated computer-aided engineering (CAE) tools since 1963


MSC Software is the developer, distributor, and

supporter of the most complete and widely-used structural analysis program in the world, MD Nastran
MSC Software is also the developer, distributor, and

supporter of the state of the art CAE analysis program, Patran


Patran is an open architecture pre- and post-processor

for all major finite element analysis (FEA) software, including MD Nastran, Marc, Dytran, and others
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-4

MSC U.S. TECHNICAL SUPPORT


With corporate headquarters in Santa Ana, California,

MSC Software maintains regional sales and support offices throughout the US:
The MSC Software technical support hotline (1-800-732-7284) is

staffed Monday through Friday 7:00 a.m. to 3:00 p.m. PST


Fax number is (714) 784-4056

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-5

MSC WORLDWIDE TECHNICAL SUPPORT


MSC.Software also maintains offices worldwide

If appropriate, your course instructor will provide information for accessing and contacting MSC support in your area

Sign up to the MSC Forums and become a member of our talented

community at: http://forums.mscsoftware.com/


Methods for contacting the MSC global support team:

Email support for Patran is via: mscpatran.support@mscsoftware.com Email support for Fatigue is via: mscfatigue.support@mscsoftware.com Website support at: http://www.mscsoftware.com/support This information is also available in the Nastran and Patran release guides
S1-6

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

OVERVIEW OF DURABILITY AND FATIGUE LIFE ANALYSIS

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-7

WHAT IS DURABILITY?
Durability is
the ability to do what its supposed to for as long as its supposed to do it!

Reliability is
having half a chance of doing what its supposed to for as long as its supposed to do it!

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-8

DEFINITION OF FATIGUE
According to BS 7608: fatigue is the damage of a structural part by the initiation and gradual propagation of a crack or cracks caused by repeated applications of stress
From a practical point of view, fatigue is:
a process where repeated variations in loading cause failure

even when the nominal stresses are below the material yield strength; and is made up of crack initiation and subsequent crack growth as a result of cyclic, plastic deformation.
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-9

THE PHYSICAL BASIS OF FATIGUE


Fatigue failures typically start at the surface of a

specimen or component
Fatigue failures start at small microscopic cracks and

accordingly are very sensitive to even minute stress raisers


The process of fatigue encompasses the entire range

from the formation of a microcrack in a persistent slip band to the propagation of a long crack in an elasticplastic continuum.
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-10

THE PHYSICAL BASIS OF FATIGUE (CONT.)


There are many ways of starting a small crack:
cracking or debonding of second phase particles; natural scratches and machining marks on the surface; corrosion pits or intergranular attack; porosity from casting; laps from forging and forming; brittle surface layers

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-11

CRACK INITIATION & GROWTH: STAGE I AND II

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-12

CRACK INITIATION & GROWTH: STAGE I AND II (CONT.)

~1mm

Persistent Slip Band Formation


PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

Stage I Crack Growth


S1-13

Stage II Crack Growth

A SHORT HISTORY OF FATIGUE

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-14

THE EARLY DAYS OF FATIGUE


Over design 42 Under design 7

Product life used to be a hit and miss affair


PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-15

A SHORT HISTORY OF FATIGUE


1828 ALBERT tests mine hoist chains under cyclic loading PONCELET designs mill wheels with cast iron axles. First uses the term fatigue in a book on mechanics IMechE debate the "CRYSTALLIZATION" theory

1839

1849

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-16

A SHORT HISTORY OF FATIGUE (CONT.)


1850+ WHLER conducts first systematic fatigue investigations on axles:

Develops the ROTATING-BENDING fatigue test Concept of FATIGUE LIMIT Development of fatigue design strategies Identifies importance of cyclic & mean stresses Recognizes the effect of notches S-N Curves appear some thirty years later

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-17

A SHORT HISTORY OF FATIGUE (CONT.)


Wohlers Railway Component Test Rig

Whler measured the compression of railway bogie suspensions to determine maximum service loads on axles. In-service loading was simulated by rotating-bending tests
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-18

A SHORT HISTORY OF FATIGUE (CONT.)


Some of Wohlers data for rotating bending tests Stress Amplitude

Unnotched Shaft

Notched Shaft

Log (Fatigue life)


PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-19

A SHORT HISTORY OF FATIGUE (CONT.)


1864 FAIRBAIRN experiments with repeated loads 1886 BAUSCHINGER first documents stress-strain HYSTERESIS 1903 EWING & HUMPHREY disprove the Crystallization theory and show that fatigue occurs due to SLIP 1910 BAIRSTOW investigates stress-strain response during cycling - develops concepts of cyclic HARDENING and SOFTENING 1920 GRIFFITH investigates cracks in glass - the birth of FRACTURE MECHANICS
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-20

A SHORT HISTORY OF FATIGUE (CONT.)


1955 MANSON & COFFIN investigate fatigue under STRAIN conditions, thermal cycling and low cycle & plastic strain considerations 1959 PARIS & ERDOGAN present first systematic method for handling crack propagation using FRACTURE MECHANICS 1961 FORSYTH identifies stage I and II crack propagation 1961 NEUBER proposes a method for estimating elasticplastic stresses and strains at stress concentrations 1968 MATSUISHI & ENDO present the rainflow method for cycle counting
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-21

A SHORT HISTORY OF FATIGUE (CONT.)


1968 TOMKINS - high strain crack propagation law physical basis for Coffin-Manson 1976 KITAGAWA & TAKAHASHI - rationalised the fatigue limit and the fatigue threshold
Failure
Fa tig u e th re sh o

Log (Stress range)

Fatigue limit

Safe

ld

Log (Crack size)


PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-22

A SHORT HISTORY OF FATIGUE (CONT.)


Battelle Study 1982
...Between 80 - 90% of all

structural failures occur through a fatigue mechanism


...The estimated annual cost of

fracture and fatigue to the US was 4.4% of GDPand could be reduced by 29% by application of current technology
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-23

A SHORT HISTORY OF FATIGUE (CONT.)


1982 nCode (UK) established to market fatigue life estimation software & consultancy services 1986 BROWN devises a fatigue map to identify the dominant mechanisms 1990 P/FATIGUE launched by PDA Engineering (now MSC Fatigue) 2003 MSC & nCode partnership to co-develop fatigue analysis software

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-24

FATIGUE FAILURE & EDUCATION


"Despite 150 years of fatigue research, unintended fatigue failures still occur. More research will NOT reduce the incidence of fatigue failure - more education will!"
Prof. D. Socie University of IIIinois,1990

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-25

USE OF FATIGUE TECHNOLOGY

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-26

USE OF FATIGUE TECHNOLOGY


Fatigue analysis is not new (60-170 years old); A collection of empirical rules to fit observed behaviour; Does not require the engineer exploiting it to understand

all the finer points;


Can be used (with training and experience) to achieve

Integrated Durability Management (IDM) goals.

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-27

FATIGUE CALCULATIONS IN
Concept design phase:
Analytical loads, previous design loads, estimated properties, early design optimization

Verification phase:
Measured loads, real properties, design refinement and optimization

Production phase:
Continued development, new markets, firefighting

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-28

WHO USES FATIGUE ANALYSIS?


Design engineer:
Design optimization for durability on the virtual component

Development engineer
Measures data on the real component, tells the design analyst where its wrong and how to fix it.

Test rig engineer


Pre-predicts rig tests and edits out non damaging cycles to speed them up.

Production engineer
Investigates service failures, monitors production, feeds back improvement ideas.
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-29

DESIGNING AGAINST FATIGUE FAILURE


Requirements:
Higher Performance Lower Weight Longer Life Reasonable Cost As Soon As Possible

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-30

DESIGNING AGAINST FATIGUE FAILURE (CONT.)


Constraints:
Life calculations are much less precise than strength calculations Fatigue properties can not be inferred from static mechanical

properties Laboratory tests often exhibit scatter and are difficult to translate to full size components Full scale prototype testing is often required to confirm an acceptable life Designs should be defect tolerant - stressing and materials selection to ensure slow crack growth and detectability before failure Designs should be Fail Safe, where possible

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-31

DESIGN APPROACHES
SAFE LIFE
Evaluate expected life, use a margin of safety, design to survive expected service life, and then retire.

FAIL SAFE
Provides redundant load paths, design to fail into a safe condition and survive until repair.

DEFECT TOLERANCE
Assumes flaws do exist, design to live with some crack growth below critical size, requires regular inspections.

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-32

WHAT DRIVES DURABILITY MANAGEMENT?

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-33

GOALS, DRIVERS & REALITIES


Competition requires FASTER concept-to-customer. Costs/profits require CHEAPER products, materials and

manufacturing processes.
Functionality requires BETTER products with high-tech features and

performance.
Legislation requires products with LONGER life, more reliable

durability and inspection periods.


The customer requires the last mile/flight/hour to be the same as the

first.
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-34

PRODUCT DEVELOPMENT LIFE CYCLE

Production

Cumulative Cost

Production Engineering Prototype Mechanical Prototype Concept Concept

Pilot Engineering Prototype DESIGN

FIX

TEST

VPD (CAE) for Durability

Mechanical Prototype
Traditional Design Development VPD Design Objectives

Development Time

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-35

TRADITIONAL APPROACH: BUILDTESTFIX


Generate idea Build it

Fix it

Test it

OK?
YES

NO

NO Out of time? YES

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

Begin Production
S1-36

INCLUDE CAE: ANALYSE & OPTIMISE FIRST


Generate idea Analyse Optimize
NO

Previous experience

OK?
YES

Build it Correlate test & analysis


NO
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

Test it

Measure
YES

OK?
S1-37

Begin Production

PREDICTING PRODUCT LIFE: BUILD & USE

Customer Usage

Product Life Check Life Based on Customer Usage

Build it and Use It

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-38

PREDICTING PRODUCT LIFE: ADD SIGN-OFF TESTING

Customer Usage

Accelerated Sign-off Test

Product Life

Re-Design

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-39

PREDICTING PRODUCT LIFE: ADD SIMULATED TESTING

Customer Usage

Accelerated Sign-off Test

Simulated Component Test

Product Life

Measured Service Loading Re-Design

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-40

PREDICTING PRODUCT LIFE: ADD CAE


Customer Usage Accelerated Sign-off Test Simulated Component Test Product Life

Measured Service Loading Stress Analysis Material Properties CAE Fatigue Simulation

Correlation

Product Life

Re-Design Optimize
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-41

OVERVIEW OF FATIGUE LIFE CALCULATION METHODS

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-42

FATIGUE LIFE METHODS


S-N (Stress-Life Method)
Relates nominal or local elastic stress to total life

E-N (Strain-Life Method)


Relates local strain to crack initiation life

LEFM (Crack Propagation Method)


Relates stress intensity to crack propagation rate

All methods rely on SIMILITUDE


PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-43

S-N METHOD
Also known as Stress-Life and Total Life Method Estimates the total fatigue life to catastrophic failure Fatigue life computed from log stress vs log cycles

(S-N) curve.
Method is appropriate for long life fatigue problems where

there is little plasticity since the method is based on nominal elastic stress
Fatigue life estimates are associated with a probability of

failure due to the large amount of scatter in the S-N curve.


PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-44

S-N METHOD - SIMILITUDE


Stress Amplitude Unnot ched Shaft

Notched Shaft

Life in Cycles

nom

nom
The life of this . . . . . . . . . . . . . . . . is the same as the life of this . . . . . if both are subject to the same nominal stress
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-45

E-N METHOD
Is also called the local strain approach, crack initiation

method, and strain-life approach


E-N method is one of the most common life prediction

methods used in the automotive industry


Practically, crack initiation means that a crack of around

1-2 mm has developed. This is often a high proportion of the component life.
Many automotive components are designed to survive

some significant plastic strains in use (especially on the test track!). The E-N method will handle these better than the S-N method which basically ignores plasticity.
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-46

E-N METHOD - SIMILITUDE

The crack initiation life here . . . . . is the same as it is here . . . . . if both experience the same local strains
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-47

STRAIN-LIFE (E-N) CURVE


Also known as Low Cycle Fatigue or Local Strain Approach Local strains can be elastic or plastic hence its suitability for

low cycle fatigue.

Plastic (Low Cycle Fatigue Line)

Elastic (High Cycle Fatigue Line)

N
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-48

S-N AND E-N FATIGUE CURVES COMPARED


Low Cycle Region (EN Method) High Cycle Region (SN or EN Method) E-N Curve 'Infinite Life' S-N Curve

S-N & E-N curves coincide in high cycle region because nominal stresses will be linear elastic E-N can also be used in low cycle region. S-N cannot, because linear stress-strain relationship is invalid

1000 Cycles

10 7 Cycles

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-49

CRACK PROPAGATION (LEFM) METHOD


What remnant life is there after initiation? What is the safe life or inspection schedule for a

component that is or may be cracked?


The crack growth method is based on the principles of

Linear Elastic Fracture Mechanics (LEFM)


It relates stress intensity factors to crack growth rates It uses cycle-by-cycle calculations to predict lifetimes It is frequently used in Aerospace, Offshore, and Power

Generation industries
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-50

CRACK PROPAGATION METHOD - SIMILITUDE

This crack . . . . . . . grows at the same rate as this one if both experience the same stress intensity factors
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-51

SUMMARY OF METHODS Nf = Ni + Np
Total Life = Crack Initiation + Crack Growth

S-N
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

Local Strain
S1-52

LEFM

INTEGRATED DURABILITY MANAGEMENT

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-53

INTEGRATED DURABILITY MANAGEMENT ACTIVITIES


DESIGN ANALYSIS
Structural Integrity Optimization

Analytical Loads Kinematic Modelling

Modern Integrated Approach


DATA & CORRELATION

DATA

CORRELATION

DEVELOPMENT ANALYSIS
Characterisation Correlation with FEA Assess Modifications

MEASURED STRAINS & LOADS


Measurement Validation Correction

DATA

DATA

SIMULATION TEST
Verification Monitoring Correlation

DATA

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-54

INTEGRATED APPROACH TO DURABILITY


Facts:
Testing is not a good way to optimize designs, but is always

required for sign-off.


Useful fatigue analysis requires verification and good test-based

information.
Neither testing nor analysis have exclusively the right fatigue

answer; therefore its not an argument between rivals.


Best results are obtained when an integrated approach is

adopted incorporating analysis and testing.


PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-55

HOW TESTING SUPPORTS ANALYSIS


Provision of load data Provision of material fatigue properties Verification of stress/strain analysis results Correlation of life predictions Final sign-off
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-56

HOW ANALYSIS SUPPORTS TESTING


Eliminate unnecessary tests Test acceleration Gauge type selection and positioning Test design

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-57

AN OVERVIEW OF VIRTUAL DURABILITY

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-58

VIRTUAL DURABILITY ANALYSIS


FE stress analysis is a pre-processing activity for durability

analysis
The essential requirement is for good local stress

information in the critical areas


Loading information can be:
Assumed (idealized loading), Experimentally acquired Semi-analytical loads Computed (full analytical loads)
PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation S1-59

VIRTUAL DURABILITY ANALYSIS (CONT.)


Achieving Faster, Cheaper, Better in Integrated Durability Management requires:
Integrated multi-disciplinary teams. Integrated software tools common to all departments. Integrated data exchange within company structure. Integrated data exchange between the company and

its suppliers and service providers.

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-60

Engineering is the art of being approximately right rather than exactly wrong.
Prof. Rod Smith University of Sheffield,1990

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-61

PAT318, Section 1, September 2008 Copyright 2008 MSC.Software Corporation

S1-62

Вам также может понравиться