Nyquist / Haghighi

ABE 601

ANSYS Tutorial Performing a Fatigue Analysis

A flat leaf spring has been machined from AISI 1050 steel cold-drawn steel (Youngs Modulus is 210 GPa, Poissons ratio is 0.3, Yield Strength is 580 MPa and the Ultimate Strength is 690 MPa).

60 cm

Applied Load 1 cm Applied Load

Four load cases are applied to the two corners of the free end of the spring: a. 50 N at each corner. The time at the end of the load step is 10 seconds. b. -50 N at each corner. The time at the end of the load step is 20 seconds. c. 74.5 N at each corner. The time at the end of the load step is 30 seconds. d. -74.5 N at each corner. The time at the end of the load step is 40 seconds. The material fatigue properties are described by: Number of Cycles, N < 103 10 to 10 > 10
6 3 6

Fatigue Strength, Sf 0.9Su

( 0.9Su )
Se

(1/ 3) log ( 0.9 Su / Se )

Se

where Su is the ultimate strength and Se is the endurance limit (fatigue limit). Assume the ratio Se/Su is equal to 0.6. The events to be used in the analysis are: Event Load Loading No. No. 1 1 50 N Load 1 2 -50 N Load 2 1 74.5 N Load 2 2 -74.5 N Load

Number of Repetitions 500,000 500,000 5,000 5,000

Scale Factor 1 1 1 1

Nyquist / Haghighi

ABE 601

The following is the step-by-step procedure for the beam deflection problem using the ANSYS GUI (Graphic User Interface) environment. Using the left button of the mouse, click on everything that is typed bold and type everything that is italicized below. (Go to Main Menu) Preprocessor Element Type Add/Edit/Delete Add Structural & Solid & Quad 4 node 42 & OK Material Props Material Models Structural Linear Elastic Isotropic EX = 210e5 PRXY = 0.3 & OK Modeling Create Areas Rectangle By Dimensions (Click X1 box) 0 (Click X2 box) 60 (Click Y1box) 0 (Click Y2 box) 1 & OK Meshing Mesh Tool Click on the Lines Set button Pick lines 2 & 4 & Apply NDIV = 4 SPACE = -2 & Apply Pick lines 1 & 3 & Apply NDIV = 30 SPACE = -2 & OK Click the Mesh Button Pick All & OK Solution Analysis Type New Analysis Choose Transient & OK & OK Soln Controls Basic Tab Time at end of loadstep: 10

Nyquist / Haghighi

ABE 601

Transient Tab Choose Stepped Loading & OK Define Loads Apply Structural Displacement On Lines Pick line 4 & OK Select All DOFs Displacement Value = 0 & OK Force/Moment On Keypoints Pick keypoints 2 & 3 & OK Direction of Force/Moment: FY Force/Moment Value: 50 & OK Load Step Opts Write LS File Load step file number n: 1 & OK Analysis Type Soln Controls Basic Tab Time at end of loadstep: 20 & OK Define Loads Delete Structural Force/Moment On Keypoints Pick All & OK Apply Structural Force/Moment On Keypoints Pick keypoints 2 & 3 & OK Direction of Force/Moment: FY Force/Moment Value: -50 & OK Load Step Opts Write LS File Load step file number n: 2 & OK Analysis Type Soln Controls Basic Tab Time at end of loadstep: 30 & OK

Nyquist / Haghighi

ABE 601

Define Loads Delete Structural Force/Moment On Keypoints Pick All & OK Apply Structural Force/Moment On Keypoints Pick keypoints 2 & 3 & OK Direction of Force/Moment: FY Force/Moment Value: 74.5 & OK Load Step Opts Write LS File Load step file number n: 3 & OK Analysis Type Soln Controls Basic Tab Time at end of loadstep: 40 & OK Define Loads Delete Structural Force/Moment On Keypoints Pick All & OK Apply Structural Force/Moment On Keypoints Pick keypoints 2 & 3 & OK Direction of Force/Moment: FY Force/Moment Value: -74.5 & OK Load Step Opts Write LS File Load step file number n: 4 & OK Solve From LS Files Starting LS file number: 1 Ending LS file number: 4 File number increment: 1 & OK

Nyquist / Haghighi

ABE 601

(Go to Main Menu) General Postproc Read Results By Pick Select Set 1 & Read & Close

Steps to perform the Fatigue Analysis Definitions used in performing a fatigue analysis: Location: a node in the model for which fatigue stresses are to be stored. Event: a set of stress conditions that occur at different times during a unique stress cycle. Loading: one of the stress conditions that is part of an event. (Go to Main Menu) General Postproc Fatigue Property Table S-N Table (Click N1) 10 (Click S1) 62.1e3 (Click N2) 1000 (Click S2) 62.0e3 (Click N3) 10000 (Click S3) 51.2e3 (Click N4) 100000 (Click S4) 42.2e3 (Click N5) 1000000 (Click S5) 34.8e3

Nyquist / Haghighi

ABE 601

Stress Locations NLOC = 1 NODE = 65 (node along the surface at the fixed end of the beam TITLE = Fixed End & Apply

Nyquist / Haghighi

ABE 601

NLOC = 2 NODE = 54 (node along the surface in the middle of the beam) TITLE = Middle & Apply NLOC = 1 NODE = 32 (node along the surface at the free end of the beam) TITLE = Free End & OK

Store Stresses From rst File NODE: 65 Event: 1 Loading: 1 & Apply NODE: 54 Event: 1 Loading: 1 & Apply NODE: 32 Event: 1 Loading: 1 & OK

Nyquist / Haghighi

ABE 601

Read Results By Pick Select Set 2 & Read & Close Fatigue Store Stresses From rst File NODE: 65 Event: 1 Loading: 2 & Apply NODE: 54 Event: 1 Loading: 2 & Apply NODE: 32 Event: 1 Loading: 2 & OK Read Results By Pick Select Set 3 & Read & Close Fatigue Store Stresses From rst File NODE: 65 Event: 2 Loading: 1 & Apply NODE: 54 Event: 2 Loading: 1 & Apply NODE: 32 Event: 2

Nyquist / Haghighi

ABE 601

Loading: 1 & OK Read Results By Pick Select Set 4 & Read & Close Fatigue Store Stresses From rst File NODE: 65 Event: 2 Loading: 2 & Apply NODE: 54 Event: 2 Loading: 2 & Apply NODE: 32 Event: 2 Loading: 2 & OK Assign Events NEV = 1 CYCLE = 500000 TITLE = Load 1 & Apply

NEV = 2 CYCLE = 5000 TITLE = Load 2 & OK Calculate Fatig & OK

Nyquist / Haghighi

ABE 601

Results:

Location: 1 Node 65 at the fixed end. The combination of event 2, load 1 and event 2, load 2 produces an alternating stress intensity of 55744 N/cm2. The spring was subjected to 5000 cycles while from the S-N Table, the maximum number of cycles allowed at that stress intensity is 3595. The partial usage value, 1.39063, is the ratio of cycles used/cycles allowed. The combination of event 1, load 1 and event 1, load 2 produces an alternating stress intensity of 37412 N/cm2. The spring was subjected to 500,000 cycles while from the S-N Table, the maximum number of cycles allowed at that stress intensity is 421,300. The partial usage value, 1.18669, is the ratio of cycles used/cycles allowed. The Cumulative Fatigue Usage value is sum of the partial usage factors (Miners rule).

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Nyquist / Haghighi

ABE 601

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