WEBINAR – FEMFAT BASICs
Axel Werkhausen
April 30th , 2014
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Profile
• The Speaker: Axel Werkhausen
•
•
•
•
FEMFAT Support & Sales since 2/2002
High School for Mechanical Engineering (5 years)
University of Linz (Technical Mathematics)
Consulting in Structural Analysis Department in ECS
• The Product: FEMFAT BASICs in brief:
•
Fatigue analysis for unidirectional loadings
•
Aside the loading assembly loads, constant loads and residual stresses can be
considered
•
A database of 400 materials (ferrous and non-ferrous) available; can be
modified/improved by the user for best correlation with physical tests.
•
The methods have been developed in a consulting & service related industry by
engineers for engineers – no black box usage.
•
Coming from Automotive industry where crack initiation equals failure, this is the
need for the analysis with 2 big “W”:
WHY and WHERE
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Crack Location Depending on The Load Level
Crack Location
Amplitude
Torsional Torque
S/N Curve
Load Cycles
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Type of Loading: Influence on S/N Curve
EN-GJS-400-18
GGG40
 Tension/Compression
F
F
a Ten/Comp135 N/mm2
185 / 135 = 1,37
 Bending
MB
MB
a Bending 185 N/mm2
 Torsion
MT
MT
a Torsion 120 N/mm2
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
FEMFAT Integration to your Process Chain
FEA
Preprocessor
HYPERMESH
FEA
Postprocessor
Graphical
Presentation
OPTISTRUCT
RADIOSS
MOTIONSOLVE
Interface
Files
HYPERSTUDY
Nodes
Elements
PODs
Groups
And OTHERS
FEMFAT
Visualizer
FEA
Solver
Interface
Files
Interface
Files
Stresses
Damage
Safety Factors
Fatigue Life,…
textfiles
MBSRPC
/ MD
III
Load Histories
Load Spectra
FEMFAT
Interface Files
MBS or
Measurement
….
BASIC
MAX
WELD
SPOT
PLAST
BREAK
STRAIN
HEAT
Material
Data Base
Material
Generator
Haigh Diagrams
S/N Curves
Casting Data
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
FEMFAT Modules
FEMFAT BASIC
BASIC
VISUALIZER
PLAST
BREAK
HEAT
MEHD
MNOISE
FEMFAT MAX
FEMFAT WELD
FEMFAT STRAIN
 Simple loading definition
 Large material data base
 Complete CAE-interfaces
 Finite life & endurance analysis
 Comprehensive fatigue influences
FEMFAT SPOT

FEMFAT LAB
k ... S/N exponent
E
ndu
LCF
HCF
 103 - 104
NEndu
CYCLES N (log)
 106 - 107
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
If linear stress analysis was performed
FEMFAT BASIC
VISUALIZER
PLAST
PLAST
BREAK
HEAT
MEHD
MNOISE
FEMFAT MAX
FEMFAT WELD
FEMFAT STRAIN
 Linear FEA stress input
 Neuber plastic stress approximation

2A, el
 M, el
FEMFAT SPOT
 M, pl
2
FEMFAT
LAB
A, pl

 Considering Sequence influence
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
S/N Curve: Useful Formulas
S/N Curve Depends on
 Material
 Stress Condition
 Geometry
 Temperature
 Surface Roughness
 Surface Treatments
 Production,…
Log (Stress Amplitude)
A1
A2
k
N1
N2
Log (Load Cycles)
d
n
N
k
  A1 
N
d

  2  1
N1 d 2
  A2 
  A1 

d1  d 2  
  A2 
  A1 

ln

k   A2 
 N2 

ln
 N1 
k
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
FEMFAT –local stress with influence parameter concept
Notch Influence
(Stress
Plastic
Gradient)
….
Thermo
Fiber
Mechanical
Statistic
Orientation
Temperature
Mean
Isothermal
….
Stress
Temperature
Tempering
….
Boundary
Effective
Layer
Plastic
Cast Micro
Strain
Structure
type of
Technological
loading
Size
Surface
Treatment
Surface
Roughness
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
FEMFAT for Structural Analysis
Mass Balance Unit
Crack Location in Test
Minimum Endurance Safety
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Let’s Get Started
• Life demo of a simple specimen with a notch under tensile load
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
FEMFAT by Engineering Center Steyr GmbH & Co KG
(short: ECS or MAGNA POWERTRAIN or MPT or STEYR)
1899
1957
1914
TORONTO CANADA
J. PUCH Erste Steierm.PUCHWERKE AG
Fahrrad-Fabriks AG
Graz
1928
AUSTRO-DAIMLERPUCHWERKE AG
1899
1934
Österr.
DAIMLER Motorenges.
Wr. Neustadt
STEYR-DAIMLER-PUCH AG
1864
1926
J. & F.
Werndl & Coomp.
STEYR
STEYR-WERKE AG
VERSION HISTORY
2.0 in 1988 ,…, 5.1 in 2014
1998
1989
1995
Truck Division
of SDP
acquired by MAN
Engineering
Center
Steyr
2001
2005
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Next Webinar to come ( Wednesday May 14th 2014)
Topics to be touched:
• FatigueLifePrediction for multi axial loaded components
• Multi Axial can be in “axes” like on physical testbench
• Multi Axial can be caused by independent loadings over time (transient)
• How to solve for an equivalent stress from stress tensors in time
• The critical cutting plane approach – important but not always sufficient ?
• Multi Axiality can also be born by materials (Short Fibre Reinforced Plastics)
• The easy setup for analysis in the software FEMFAT max
• The other way to use channelMAX: modal fatigue analysis
• The other way to use transMAX: safety factor analysis in railway industries