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COURSE OBJECTIVES
Solve durability problems using MSC Fatigue. Students will work through a number of workshop problems in
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.
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COMPANY OVERVIEW
The MSC Software Corporation has been supplying
supporter of the most complete and widely-used structural analysis program in the world, MD Nastran
MSC Software is also the developer, distributor, and
for all major finite element analysis (FEA) software, including MD Nastran, Marc, Dytran, and others
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MSC Software maintains regional sales and support offices throughout the US:
The MSC Software technical support hotline (1-800-732-7284) is
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If appropriate, your course instructor will provide information for accessing and contacting MSC support in your area
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
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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!
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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.
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specimen or component
Fatigue failures start at small microscopic cracks and
from the formation of a microcrack in a persistent slip band to the propagation of a long crack in an elasticplastic continuum.
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~1mm
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1839
1849
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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
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Whler measured the compression of railway bogie suspensions to determine maximum service loads on axles. In-service loading was simulated by rotating-bending tests
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Unnotched Shaft
Notched Shaft
Fatigue limit
Safe
ld
fracture and fatigue to the US was 4.4% of GDPand could be reduced by 29% by application of current technology
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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
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Development engineer
Measures data on the real component, tells the design analyst where its wrong and how to fix it.
Production engineer
Investigates service failures, monitors production, feeds back improvement ideas.
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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
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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.
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manufacturing processes.
Functionality requires BETTER products with high-tech features and
performance.
Legislation requires products with LONGER life, more reliable
first.
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Production
Cumulative Cost
FIX
TEST
Mechanical Prototype
Traditional Design Development VPD Design Objectives
Development Time
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Fix it
Test it
OK?
YES
NO
Begin Production
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Previous experience
OK?
YES
Test it
Measure
YES
OK?
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Begin Production
Customer Usage
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Customer Usage
Product Life
Re-Design
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Customer Usage
Product Life
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Measured Service Loading Stress Analysis Material Properties CAE Fatigue Simulation
Correlation
Product Life
Re-Design Optimize
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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
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
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E-N METHOD
Is also called the local strain approach, crack initiation
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.
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The crack initiation life here . . . . . is the same as it is here . . . . . if both experience the same local strains
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N
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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
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Generation industries
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This crack . . . . . . . grows at the same rate as this one if both experience the same stress intensity factors
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SUMMARY OF METHODS Nf = Ni + Np
Total Life = Crack Initiation + Crack Growth
S-N
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Local Strain
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LEFM
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DATA
CORRELATION
DEVELOPMENT ANALYSIS
Characterisation Correlation with FEA Assess Modifications
DATA
DATA
SIMULATION TEST
Verification Monitoring Correlation
DATA
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information.
Neither testing nor analysis have exclusively the right fatigue
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analysis
The essential requirement is for good local stress
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Engineering is the art of being approximately right rather than exactly wrong.
Prof. Rod Smith University of Sheffield,1990
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