Finite Element Analysis of Durability and Fatigue Life: Ansys Ncode, Simulia FE-Safe
The demand for simulation of fatigue and durability is especially strong. Durability often dominates development agendas, and empirical evaluation is by its nature time-consuming and costly. Simulation provides a strategic approach to managing risk and cost by enabling design concepts or design changes to be studied before investment in physical evaluation. The industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life and FEMFAT used to calculate fatigue life of multiaxial, welds, short-fibre composite, vibration, crack growth, thermo-mechanical fatigue.
Based on what we want to Design and Analysis, Stress, Strain or temperature from finite element (FE) software such as ANSYS, ABAQUS, NASTRAN, LS-Dyna, MSC Marc etc used. This FEA (Finite Element Analysis) must contain correspond simulation step detail based on what we want to do in Fatigue Simulation. ESimLab engineers use different methodology for each specific industrial and research fields and multiphysics. Ansys Ncode, Simulia FE-Safe and FEMFAT are our fatigue analysis tools. With the Fatigue analysis, we can:
• Correct for mean stress and surface finish effects
• Determine a scale or fatigue concentration factor required to achieve a target life
• Review damage histograms to determine which load cycles were most damaging
• Output damage time histories to show exactly when the damage occurred
ESimLab engineers use combination of advanced numerical simulation FEA-CFD tools in conjunction with Fatigue simulation in a variety of industrial applications, including Automotive, Aerospace, Consumer Goods, Heavy Equipment, Marine, Medical Equipment, Off-highway, Offshore, Oil & Gas, Rail, Sporting Goods, Wind Energy and University/Research:
With our experience in FEA and CFD and using advanced method for Real World Simulation including Fatigue Life and Durability Prediction, Our customers could go beyond over design and minimize the cost and in the same time have a special product with maximum safety factor.
FEA and CFD Based Simulation
FEA (Finite Element Analysis) of Welding Fatigue
Industry is putting increasing pressure on manufacturers to use less material to deliver lightweight but stronger components, less warranty and recall costs and all in less time. Traditional methods of over-engineering components and expensive, open-ended test-redesign-test programs are not meeting the needs of the modern engineering company. For welded joints and welded structures, the prediction of failure locations and the calculation of fatigue lives are notoriously complex and difficult tasks, which can often result in poor correlation with test data.
ESimLab use advanced Numerical simulation software and methods to simulate the welding behavior in real service load condition and estimate its life. The Seam Weld and Spot Weld fatigue simulation enables the fatigue analysis of joints including different type of welding such as fillet, overlap, spot welds in thin sheets and laser welded joints.
FEA (Finite Element Analysis) Damage, Creep and Creep-Fatigue Interactions
In Thermo-Mechanical Fatigue Analysis, we use special solvers for high temperature fatigue and creep by using stress and temperature results from finite element simulations. Mechanical loads that vary at a different rate to the temperature variations can also be combined. Applications include components that are both mechanically and thermally loaded such as vehicle exhaust systems and manifolds. Finite Element analysis is used for stress analysis, but this does not answer the most important questions: How long will the component last in service? What design changes are needed to provide optimum durability? How does elevated temperature service reduce durability? What is the cause of failure: creep, fatigue, or creep-fatigue interaction?
With Combination of advanced FEA and Fatigue Analysis tools, we can solve complicated problem in power plant components, power station boilers, gas turbine blades and steam turbine components in high temperature field. Also this simulation is very necessary in powertrain industry (automotive exhaust components and turbocharger impellers) where creep and creep fatigue interaction is prevalent. We can Calculate this parameters based on clients needs:
• Where fatigue cracks will occur
• When fatigue cracks will occur
• How creep mechanisms will influence fatigue life
• The factors of safety on working stresses – for rapid optimization
• The endurance of components in high temperature environments where fatigue damage mechanisms and creep damage mechanisms interact to significantly reduce component life
considering Creep-Fatigue interaction in high temperature simulations identifies whether fatigue and/or creep are the dominant damaging mechanisms, thus allowing re-design to focus on the relevant damage mechanisms and significantly reduce pre-service component testing.
• Thermo-mechanical fatigue damage, creep damage through Ductility Exhaustion, and fatigue-creep interaction
• Thermo-mechanical fatigue damage and fatigue-creep damage interaction based on Strain Range Partitioning
• Inelastic Strain Range Partitioning of the strain cycle and computation of plastic-plastic (PP), creep-plastic (CP), plastic-creep (PC), and creep-creep (CC) damage
• Damage for each individual cycle, including damage for uncompleted cycles
• Advanced treatment of multiaxial stresses
FEA (Finite Element Analysis) of Vibration Fatigue
Structural vibration can be a source for many product related problems; it can cause fatigue and durability problems as well as adverse reactions to the user or bystanders in the form of undesirable vibrations that can be felt or heard. As well, undesired structural vibrations can prevent products from operating as required and potentially becoming a safety concern. The Vibration Fatigue simulation predict fatigue in the frequency domain and it is more realistic and efficient than time-domain analysis for many applications with random loading such as wind and wave loads.
• Simulates vibration shaker tests driven by random PSD, swept-sine, sine-dwell, or sine-on-random loading
• FE models are solved for frequency response or modal analysis
• Vibration loading is defined in Fatigue simulation tools and can include effect of temperature, static offset load cases and complete duty cycles of combined loading
• Vibration fatigue loads can be used for SN, EN, seam weld, spot weld
FEA (Finite Element Analysis) Composite Fatigue
The Composite Analysis option allows users to evaluate the strength of a structure against industry standard composite failure criteria. Rather than limiting this evaluation to a small number of load cases or steps, stresses can be assessed by using the chosen failure criteria throughout realistic duty cycles (quasi-static or dynamic). This allows critical locations, load combinations and associated design reserve factors to be readily identified. In addition, selected location loading paths may be visually compared with the material failure envelope. The following methods can be used individually or combined to give the most conservative result:
• Maximum stress
• Maximum strain
FEA (Finite Element Analysis) of Elastomers
Developers of rubber materials, components and systems increasingly rely on simulation as a routine means to address design issues. For metallic components, solutions for fatigue analysis from FEA have existed commercially for many years and have become an essential part of maturing and qualifying design concepts in many industrial sectors. Using modern multiaxial strain based fatigue methods enable us to simulate the fatigue analysis of elastomer materials and Rubber. Because of their macromolecular structure, elastomers exhibit unique behavior and require specialized analysis methods:
• Finite Strains
• Nonlinear Elasticity
• Strain Crystallization
• Time Dependence
• Temperature Dependence
• Ozone Attack
• Mullins Effect
• Crack closure
• Fatigue Threshold
• Microstructural crack precursor size
Finite Element based Design and Analysis of Powertrain & Engines
With using FE models of the rotation of crankshafts and the movement of pistons and conrods our engineers can simulate the material property changes for fatigue and creep-fatigue through the engine cycle including complex loading conditions, intermittent contact and complex duty cycles.
Suspension and Chassis
ESimLab engineers handle complex multiaxial road load data using PSDs, steady state modal and random transient dynamic analyses to calculate the effects of complex vibration fatigue. FE models of large flexible components and structures are analyzed efficiently and special consideration for efficient simulation of seam welds, structural welds and spot welds, performed in FEA level.
Our engineers can simulate the fatigue life of exhaust components including structural and thermal loading variations and creep and creep-fatigue interaction effects.
Durability and Fatigue Application highlights in different industry
• Aerospace: Wings, panels, engine blades, rivets, bondings, valves, nacelles, interior component, etc.
• Automotive: Chassis, rivets, bolts, wheels, connecting rods, full body systems, door, seat, dashboard, interior component, drivetrain component, underhood, oil cooler bracket, front-end carrier,Fatigue behavior of vehicle-mounted medical equipment as it interacts with the suspension dynamics of the vehicle and the road load, etc.
• Biomedical: Prosthesis, Fatigue properties of medical implants, etc.
• Energy: Pipes, vessel, valves, fan blade, pump body, Effects of the complex conditions seen in wind turbines such as vibration, the effects of rotating components and different wind states, etc.
• Electronics: Connectors, clips, electronic racks and housing assemblies,etc.
• Marine and offshore: Ship hulls and structures fatigue analysis of welded joints using FEA models, etc.
Commercial Fatigue Simulation packages:
- DesignLife developed by nCode (now HBM)
- Durabilika (Fatigue Net) developed by the team from Western Michigan University
- FATPLUS originally developed in NASA
- FAT4FEM by SAFE-FEM
- FatPro by CADLM
- FemFat by ECS Magna-Steyr
- Fe-Safe by Safe Technology
- fFatigue – a tiny but very useful freeware for fatigue calculations
- FILIPP (initiation) & RIFO (fracture mechanics) by Technical University Darmstadt
- FracSafe is prepared by employees of Fraunhofer IWM Freiburg and enables computation in accordance with FKM-Richtlinie
- Lifing – software packages allowing you to analyze fatigue crack initiation and growth respectively.
- LIMIT – software prepared by CAE Simulation Solutions involves various standards focused on analyses in welds.
- LMS Virtual.Lab Durability by LMS International
- MSC Fatigue by MSC Software
- WinLife by Steinbeis Transferzentrum
- MATDAT.com – MATerial properties DATabase and set of estimation/calculation tools for industry professionals, engineers, scientists and students.
- FADOFF databases – A set of databases on fatigue related papers, material parameters and fatigue experiments
- Bar Steel Fatigue – Database managed by Autosteel, focus on LCF
- Fatigue Calculator – Material Property Finder, which was established by Socie’s family, now managed by Altair
- MatWeb – a searchable material database
- Material database – a simple database on this website, not further extended, but still available for use
- NIMS Materials Database – resource of fatigue data concerning fatigue & creeep
- site of SAE FD&E Committee
- NASA Technical Report Server – set of many published NASA reports
Considering complexity and needs to have new procedure and constitutive equation, we must try to develop new FEA and CFD based software to overcome engineering challenges.
FEA and CFD based Programming needs experience and deep knowledge in both Solid or fluid mechanics and programming language such as Matlab, Fortran, C++ and Python.
We use subroutine’s with programming languages such as Fortan, C and Python in CFD and FEA sofware such as Abaqus, Ansys, Fluent and Star-ccm+ to add new capability and Constitutive equation.
ESimLab use Mathematical Methods and Models for Engineering Simulation. We, focuses on numerical modelling and algorithms development for the solution of challenging problems in several engineering sectors specialized in the development of software for the numerical discretization of partial differential equations, linear algebra, optimization, data analysis, High Performance Computing for several engineering applications.
Real world Simulation: Combination of experience and advanced analysis tools
Calling upon our wide base of in-house capabilities covering strategic and technical consulting, engineering, manufacturing ( Casting, Forming and Welding) and analytical software development – we offer each of our clients the individual level of support they are looking for, providing transparency, time savings and cost efficiencies.
ESimLab engineers participate in method development, advanced simulation work, software training and support. Over experiences in engineering consulting and design development, enables ESimLab’s engineering team to display strong/enormous client focus and engineering experience. The ESimLab team supports engineering communities to leverage CFD-FEA simulation softwares and methodologies. It leads to the creation of tailored solutions, aligned with the overall product development process of ESimLab clients.
CAE Simulation: CFD, FEA, System Modeling, 1D-3D coupling
Integrated expertise covering every Equipment component analysis. From concept through to manufacture and product launch, and for new designs or Equipment modifications, we provide engineering simulation expertise across projects of all sizes. Simulation has become a key enabling factor in the development of highly competitive and advanced Equipment systems. CAE methods play a vital role in defining new Equipment concepts.