Intro To ANSYS NCode DL 14 5 L02 CAE Fatigue

Introduction to ANSYS nCode DesignLife
Customer Training Material

Lecture 2: Introduction to CAE Fatigue
L2-2
ANSYS, Inc. Proprietary
2013 ANSYS, Inc. All rights reserved.
Release 14.5
April 20133
Agenda
Review basics of fatigue
what is fatigue
physics of fatigue cracks
fatigue history
fatigue testing

Introduce basics of CAE durability
fatigue approach
stress-life and strain-life
crack-growth

Introduce basics of fatigue analysis
stress cycle
cycle counting
damage accumulation

L2-3
Release 14.5
April 20133
Introduction
Fatigue damage is the initiation and/or growth of a crack under
fluctuating loading
progressive damage
component seems to lose strength and get tired after multiple load
applications, hence the name fatigue
almost all structural components are subjected to cyclic service

Time
S
t
r
e
s
s

y

Fatigue failure occurs after
repeated loadings even
though the stress is low
L2-4
Release 14.5
April 20133
Fatigue Life
Fatigue failure is typically viewed as a 3-stage phenomena
stage 1: crack initiation
stage 2: stable crack growth
stage 3: fast fracture

Fatigue life = crack initiation + crack growth
no precise transition from crack initiation to crack growth
L2-5
Release 14.5
April 20133
Surface flaws initiate at tiny dislocations in the materials
microstructure
very localized stress concentration
practically undetectable and impossible to model using FE

These tiny surface flaws create persistent slip bands that propagate
along the maximum shear plane under alternating stress
bands slip back and forth like a shifting deck of cards
Crack Initiation
Alternating Stress
Crystal surface
Slip bands form
along planes of
maximum shear
giving rise to
surface extrusions
and intrusions
L2-6
Release 14.5
April 20133
Slip bands grow into micro-cracks (Stage I cracks)
small compared to materials microstructure
difficult to detect, invisible to the naked eye
grow in direction of maximum shear stress
45
0
to the direction of the applied load

Stage I Cracks
L2-7
Release 14.5
April 20133
After traversing 2-3 grain boundaries, the micro-cracks grow into
fatigue cracks (Stage II cracks)
large compared to materials microstructure
crack itself physically interrupts the flow of stress
stress concentration causes plastic stresses at the crack tip
local plastic stress causes the crack to change direction
growth is now propagated by cyclic plastic stress at the crack tip
oriented perpendicular to maximum principal stress

Stage II Cracks
L2-8
Release 14.5
April 20133
Fatigue Failure
If sufficient energy exist, Stage II cracks continue to grow until tensile
failure occurs
most lack sufficient energy to propagate across grain barriers
crack arrests
fatigue damage
producing striations
(aka beach marks)
fast final fracture due
to tensile failure - no
striations
initial crack

slip bands micro-cracks fatigue cracks tensile failure

L2-9
Release 14.5
April 20133
History of Fatigue Analysis
Fatigue failures has been investigated for more than 150 years
initially applied to the study axel failures in the railroad industry
first industrial components to be subjected to millions of cycles
failures continue
L2-10
Release 14.5
April 20133
1837 - Wilhelm Albert publishes the first article on fatigue
1860 August Whler devises a test for fatigue
1901 - O.H. Basquin proposes a log-log relationship for S-N curves

1945 - A.M. Miner introduces a linear damage hypothesis
1958 - Fatigue crack growth explained in terms of plastic strain
1968 - Tatsuo Endo introduces the rainflow cycle count algorithm
Key Events in Fatigue Analysis
L2-11
Release 14.5
April 20133
Fatigue Analysis
Initially fatigue analysis was done after an in-service failure, if at all
build > break > redesign
Customer
Usage
Life
Re-Design
L2-12
Release 14.5
April 20133
Incorporating Fatigue Testing
As customer usage became better understood, it was applied to
fatigue testing
build > test > redesign

Customer
Usage
Test Life
Re-Design
L2-13
Release 14.5
April 20133
Fatigue Testing Limitations
Fatigue testing has many limitations
requires many physical prototypes
realistic tests are difficult or impossible to achieve
slow and expensive
fails to deal with over-design
difficult to handle late changes and design variations
test results may differ significantly
requiring statistical interpretation

L2-14
Release 14.5
April 20133
CAE Fatigue Analysis
CAE can predict fatigue damage in a virtual environment
evaluations can be performed during design phase
can assess cumulative damage caused by multiple loads
L2-15
Release 14.5
April 20133
5 Box Trick
CAE fatigue analysis are built around five basic actions
so called 5 box trick
inputs > pre-processing
solver post-processing
L2-16
Release 14.5
April 20133
CAE Durability Approaches
Two basic approaches for performing CAE durability analysis
fatigue approach
fracture mechanics
also known as crack-growth or crack-life method

Fatigue approach
use calculated stresses/strains and material fatigue curve to predict
cycles to failure (life)
two basic fatigue analysis approaches
stress-life (SN)
uses elastic stresses
strain-life (EN)
uses elastic-plastic strains
L2-17
Release 14.5
April 20133
CAE Fatigue Methods
Stress-life (SN) uses elastically calculated stress and stress vs. cycle
fatigue failure curves (S-N curves)
assumes stress drives fatigue
only applicable high cycle fatigue
greater than 100,000 cycles for ductile metals

Strain-life (EN) uses elastic-plastic strains and Strain Life
Relationship Equation
assumes local plastic strains drives fatigue
applicable to low and high cycle fatigue
L2-18
Release 14.5
April 20133
Stress-Life Approach
Stress-life (SN) fatigue method assumes that fatigue damage is
produced by fluctuating stresses
only applicable to elastic stress, so limited to limited to low stress/high
cycle applications
usually more than 100,000 cycles to failure for ductile metals
fatigue life is based on alternating stress range and Whler fatigue curve
(S-N curves)
original numerical fatigue approach
vast amount of industry experience
simple technique
often can be checked with hand calculations

L2-19
Release 14.5
April 20133
S-N Curves
S-N curves are plots of elastic stress versus total cycles to failure
usually log-log plots
S (y-axis): either full stress amplitude or alternating stress range
N (x-axis): total cycles to failure (initiation and propagation)
L2-20
Release 14.5
April 20133
Strain-Life Fatigue
Strain-life fatigue (EN) assess fatigue damage using cyclic strain
ranges and the Strain Life Relationship equation
applicable to both low cycle and high cycle applications
stresses less than or greater than yield
uses local elastic-plastic strains
either directly calculated or adjusted from elastic results
predicts crack initiation

Relatively new fatigue analysis technique
usage began approximately 30 years ago
difficult to implement with hand calculations
limited to CAE
L2-21
Release 14.5
April 20133
Strain-Life Fatigue
EN method is based on assumption that material behavior at notch
root is analogous to small test specimen under strain controlled
conditions
F

F
overall body remains elastic
local deformation is strain controlled
behavior of notched component with localized plasticity
can be simulated using smooth test specimen

L2-22
Release 14.5
April 20133
Strain Life Relationship
( )
b
e
f
f
N
E
2
2
o c
=
A
( )
c p
f f N 2
2
c
c
=
A
( ) ( )
c b
f f f
f
N N
E
2 2
2
c
o c
+ =
A
Basquins equation
Coffin-Mansons equation
L2-23
Release 14.5
April 20133
Cyclic Loading Terms
Fatigue damage is caused a changing stress/strain state
sine curve is a simple representation of cyclic loading

stress ratio (R) = S
min
/S
max

amplitude ratio (A) = S
a
/S
m

S
a
S
a
AS
S
max
S
min
S
m
S
max
= maximum stress
S
min
= minimum stress
S
m
= mean stress
S
a
= alternating stress
S = stress range
Common loadings:
fully reversed: R = -1, A = infinity
zero to maximum: R = 0, A = 1
L2-24
Release 14.5
April 20133
CAE Cycle Counting
If multiple cyclic loadings occur, magnitude and number of each
stress/strain reversal must be determined
minimum stress, maximum stress, mean stress, and number of cycles
associated with each stress reversal must be determined

Rainflow is the most common cycle counting algorithm
applicable to stress-life (SN) and strain-life (EN) methods
automated in DesignLife

Rainflow counts number of closed strain loops

L2-25
Release 14.5
April 20133
Rainflow Cycle Counting
Rotate strain history 90 degrees and plot vs time

Cyclic behavior can be visualized as rain flowing off of a pagoda roof
fatigue cycles are:
a-d, b-c, e-f, and g-h
L2-26
Release 14.5
April 20133
Rainflow cycle counting can also be visualized as water draining
from valleys
determine peaks and valleys of stress/strain during cycling
invert stress/stain history and imagine it is filled with water
drain water - start at deepest valley and repeat until all valleys are drained
total depth drained = stress range
mean depth = mean stress
time
100
300
200
400
500
4
5
0

2
2
5
time
100
300
200
400
500
time
100
300
200
400
500
drain water starting
at lowest valley
imagine filled with
water
time
100
300
200
400
500
invert and reorder to
start with absolute max
L2-27
Release 14.5
April 20133
Rainflow approach divides any arbitrary load history into groups
(bins or blocks) of similar loading
rainflow matrix can be visualized using a histogram

Each group represents a number of loading cycles for a particular
stress range and mean stress
L2-28
Release 14.5
April 20133
Damage Accumulation
Multiple cyclic loading conditions have a cumulative fatigue effect

Rainflow groups the loading history into blocks loading blocks
each block causes a fraction of the total damage (partial damage or
damage fraction")

( )
i
i
i
N
n
D fraction damage =
D
i
= damage fraction caused by loading block (i)
n
i
= number of applied cycles of loading block (i)
N
i
= available fatigue life for loading block (i)
L2-29
Release 14.5
April 20133
Damage Accumulation
Damage fraction is the amount of life that has been used by a block
of loading

If n
i
= 1e5 and N
i
= 1e6, the damage fraction is 0.10
10% of the total fatigue life has been used up by loading block i

allowable
actual
N
n
i
i
= = fraction damage
L2-30
Release 14.5
April 20133
Miners Rule
Miners Rule assumes that the total damage is simply the linear
summation of the partial damages

first proposed by Palmgren in 1924 and further refined by Miner in 1945
also referred to as Linear Damage Rule
applicable to both SN and EN
widely used
simple to implement and as accurate as more complicated methods
load sequence is not considered
failure occurs when sum of damage fractions equals the fatigue life
D is equal to or greater than 1.0
automated in DesignLife

( )

=
= + + + =
n
i
i
i
n
n
N
n
N
n
N
n
N
n
N
n
D
1
3
3
2
2
1
1
damage total
L2-31
Release 14.5
April 20133
Accuracy
Fatigue calculations are much less precise than strength calculations
statistical, not deterministic, phenomenon
empirical rules
order of magnitude errors in life estimates are common
large factor of safety (FS) typically assumed to ensure safe design
FSs of 10 are common
CAE fatigue can enable smaller FSs
L2-32
Release 14.5
April 20133
Crack-Life Approach
Crack-life method uses fracture mechanics parameters (e.g., J-
integral, stress intensity, etc.) to predict flaw propagation under
cyclic service
typically uses Pariss Law (da/dN) to relate fracture mechanics
parameters to crack growth rate
often used to establish inspection intervals
for an inspection technique the smallest detectable flaw size is known
number of cycles required to grow a crack from smallest detectable size to
critical size is determined
inspection intervals are based on crack growth rate

ANSYS Mechanical APDL and DesignLife both have some fracture
mechanics capabilities
L2-33
Release 14.5
April 20133
Flowchart of CAE Durability Analysis
CAE Durability
Fatigue Approach
Crack Life Approach
Strain-Life (EN) Stress-Life (SN)
Paris Law
crack growth
rate
rainflow cycle counting
Miners rule damage accumulation
number of cycles
to failure (life)
L2-34
Release 14.5
April 20133
Summary
Fatigue cracks start at surface dislocations and are driven by
reversing local plastic flow

Fatigue failure occurs at stress levels insufficient to cause failure in a
single application
damage is cumulative and unrecoverable
difficult to detect progressive deterioration during fatigue process
catastrophic failures can occur without warning

Fatigue failure is typically viewed as a 3-stage phenomena
stage 1: crack initiation
stage 2: stable crack growth
stage 3: fast fracture

Fatigue life = crack initiation + crack growth

L2-35
Release 14.5
April 20133
Summary
Fatigue testing is slow and expensive

CAE durability analysis predict fatigue in a virtual environment
characterize capability of a component to survive cyclic service
known as fatigue analysis
fatigue life calculations are less precise than strength calculations

Two basic CAE durability analysis approaches
fatigue approach
stress-life (SN) or strain-life (EN)
fracture mechanics
crack life
Rainflow method commonly used to count cycles for both SN and EN
Miners Rule commonly used to accumulate damage for SN and EN
L2-36
Release 14.5
April 20133
Workshop 1
Workshop 1: WB - DesignLife interface
restore archive of existing WB project
review WB project page
review Engineering Data
open Mechanical and solve
review DesignLife results from project schematic
modify design points in Parameter Manager

Intro To ANSYS NCode DL 14 5 L02 CAE Fatigue

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