Example5 FatigueTools WS02-EN

Introduction to Workbench Simulation 12.
Workshop A10.2
Fatigue: Strain-Life
06/24/2009 Workbench 12.0 Inventory #002590

© 2009 ANSYS, Inc. All rights reserved. ANSYS, Inc. Proprietary WSA10.2-1
Fatigue Module: Strain Life
Goals Workshop Supplement
• Goal:
– A fatigue analysis will be performed using the Strain-Life approach
– A solid bracket is constrained on one end and loaded on the other end
• A load of 1000 N is applied on one end
• For fatigue calculations, a load of 3000 N will be assumed
– Fatigue calculations using the strain-life approach are performed on the
part, considering a design life of 1e5 cycles
Constraints
Applied
Load
06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.2 – Project Page Workshop Supplement
1. Start ANSYS Workbench 12.0. This brings you to a new Project

Schematic. We will use a project created in WB 11.0, so we will
need to “import” it into WB 12.0
a. In the Project Page, click on File > Import…
b. In the File Import window, change the File Type to “Workbench R10 / 11
Project”
c. Open the file named “strain-based.wbdb”
a. b.

… Workshop A10.2 – Mechanical Environment Workshop Supplement
2. Double click the “Model” cell to open the Mechanical environment

a. A separate windows for Mechanical appears
b. Note: A stress analysis of the bracket (A4) has already been set-up and
solved. Only fatigue-specific steps will be covered in this workshop
a. b.

Workshop A10.2 – Review Static Model Workshop Supplement
3. Review the mesh:

• Click on the “Mesh” branch
• Note: a more refined mesh is specified at four corners of the
bracket in anticipation of areas of high stress concentration, using
“Sizing”
4. Inspect the loads and supports:

• Click on the “Static Structural” branch
• Note: One end is constrained using a Cylindrical Support, while a
force of 1000 N is applied on the opposite end’s hole locations
5. View the static analysis results:

• Click on the “Equivalent Stress” branch to view
von Mises stress results
• Review the other results as well
. . . Workshop A10.2 – Review Fatigue Data Workshop Supplement
6. Review the fatigue properties of the material:

a. Return to the Project Schematic and double-click on the Engineering
Data cell
b. In the “Outline Filter” click on Engineering Data.
a. b.

c. Properties for Structural Steel appear at the end of the page under
“Properties of Outline Row 3: Structural Steel”
d. Click on the “+” sign to review the Strain-Life Parameters
(Check your units for consistency!)
d.
c.

e. Click on View > Chart to display the Strain-Life graph

Note that this is a log-log chart
e.

f. Plot the stress-strain curve by selecting the “Cyclic Stress Strain” as the
Display Curve Type. The cyclic parameters should be as follows:
• “Cyclic Strength Coefficient” is 1000 MPa
• “Cyclic Strain Hardening Exponent” is 0.2
• Note: In reality, although there are six parameters, only four are independent: n’ = b/c and H’ =
s’f / (e’f b/c ). However, it is common practice to derive all six constants from test data and only
satisfy this constraint approximately
– -0.106/-0.47 = 0.2255 ≈ 0.2
– 920/(0.213^-0.106/-0.47) = 1303 ≈ 1000
f.

Workshop A10.2 – Fatigue Tool Workshop Supplement
7. Insert Fatigue Tool:

1. Highlight the “Solution” branch,
RMB > Insert > Fatigue > Fatigue Tool
8. Specify “Fatigue Tool” Details:
a. Change Loading > Type > Zero-Based
b. Change “Scale Factor” to “3”
• This multiplies all static analysis results by a factor of 3.0.
While the initial linear static analysis was carried out with a
load of 1000 N, the fatigue calculations will be based on an
applied load of 3000 N.
• This feature allows users to scale loads without having
to re-run the static analysis, which may be more
computationally intensive than the fatigue calculations.
c. Change Option > Analysis Type > Strain Life
d. Leave “Mean Stress Theory” as “None”
• For this first run, no modification of strain-life
based on mean stress will be accounted for
e. Change “Stress Component” to “Signed von Mises”
f. Leave “Infinite Life” to “1e9”

Workshop A10.2 - Fatigue Results Workshop Supplement
9. Insert Fatigue Contour Results:

a. Life
b. Damage
• In the Details view, change “Design Life” to “1e5”
c. Safety Factor
• In the Details view, change “Design Life” to “1e5”
d. Biaxiality Indication

… Workshop A10.2 - Fatigue Results Workshop Supplement
e. Fatigue Graph Results > Fatigue Sensitivity

f. Fatigue Graph Results > Hysteresis (3 times)
• Note: Request Hysteresis three times. In the Object Tree,
there should be “Hysteresis,” “Hysteresis 2,” and “Hysteresis 3”
g. Select “Hysteresis 2” and, in the Details
view, change Scope > Geometry to the fillet e. & f.
shown on the bottom. Also, change
Options > Points per Segment to 100
g.

… Workshop A10.2 - Fatigue Results Workshop Supplement
h. Similarly, select “Hysteresis 3” and, in the Details view, change

Scope > Geometry to the fillet shown on the bottom. Also, change
Options > Points per Segment to 100
h.

Workshop A10.2 – Solve and Review Results Workshop Supplement
10. Click on the “Solve” icon to initiate the fatigue analysis:

• Note: Since the linear static analysis has already been completed, only the fatigue calculations need to
be run
11. Review fatigue results:
a. Plot the “Damage” variable using isolines
• Note: The amount of damage present on the top and bottom fillets are close. This is because
although the load is Zero-Based, no correction is made for tensile vs. compressive stresses
• Both “Damage” and “Safety Factor” show that the current design life of 1e5 cycles will not be
met

Workshop A10.2 - Review Fatigue Results Workshop Supplement
b. “Hysteresis 2” and “Hysteresis 3” show the cyclic stress-strain behavior

at the top and bottom fillets, respectively. As is apparent from the
curves, the top fillet is in compression while the bottom one in tension.
If “Signed Von Mises” were not used, both results would be the same,
since Equivalent (von Mises) stress is always positive.
Top Fillet Bottom Fillet

Workshop A10.2 – Re-run Fatigue Calculations Workshop Supplement
12. Click on the “Fatigue Tool” and

change “Mean Stress Theory” from
“None” to “SWT”
• Note: with this option, mean stress correction will be
accounted for both tensile and compressive mean
stresses
13. Re-run the fatigue calculations by

clicking on the “Solve” icon

Workshop A10.2 - Review New Fatigue Results

Workshop Supplement
14. Review “Damage”

• This example shows the difference of using no mean stress correction with
using SWT
• Note that, unlike the case with no stress correction, the top and bottom fillets
report different amounts of damage. This is because the top is in compression
and the bottom is in tension. With the SWT mean stress correction,
compressive mean stresses increase life while tensile mean stresses decrease it
No Mean Stress Correction SWT Mean Stress Correction

… Workshop A10.2 - Review New Fatigue Results

Workshop Supplement
15. Select “Biaxiality Indication”

a. Click on the Max Value on the contour legend and change it to 1
b. Click on the Min Value on the contour legend and change it to -1
c. Click on one of the legend color bars and use the “+”“-” signs to
decrease the number of contour bands to 3
d. The contour band should now resemble the one shown below
a.
c.
d.
b.
… Workshop A10.2 - Review New Fatigue Results

Workshop Supplement
• Values of “0” correspond to uniaxial stress, “1” indicates a biaxial state of

stress, and “-1” indicates pure shear state. This helps users to determine
what the stress state is in different regions since the fatigue tests are done
assuming a particular state of stress. In this example, the critical fillet
regions report values near zero (green), so the fatigue assumptions may be
valid if the fatigue testing was done on uniaxial specimens.


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Introduction to Workbench Simulation 12.

06/24/2009 Workbench 12.0 Inventory #002590

Goals Workshop Supplement

06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.2 – Project Page Workshop Supplement

1. Start ANSYS Workbench 12.0. This brings you to a new Project

06/24/2009 Introduction to Workbench Simulation Inventory #002590

… Workshop A10.2 – Mechanical Environment Workshop Supplement

2. Double click the “Model” cell to open the Mechanical environment

06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.2 – Review Static Model Workshop Supplement

3. Review the mesh:

4. Inspect the loads and supports:

5. View the static analysis results:

. . . Workshop A10.2 – Review Fatigue Data Workshop Supplement

6. Review the fatigue properties of the material:

06/24/2009 Introduction to Workbench Simulation Inventory #002590

. . . Workshop A10.2 – Review Fatigue Data Workshop Supplement

06/24/2009 Introduction to Workbench Simulation Inventory #002590

. . . Workshop A10.2 – Review Fatigue Data Workshop Supplement

e. Click on View > Chart to display the Strain-Life graph

06/24/2009 Introduction to Workbench Simulation Inventory #002590

. . . Workshop A10.2 – Review Fatigue Data Workshop Supplement

06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.2 – Fatigue Tool Workshop Supplement

7. Insert Fatigue Tool:

06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.2 - Fatigue Results Workshop Supplement

9. Insert Fatigue Contour Results:

06/24/2009 Introduction to Workbench Simulation Inventory #002590

… Workshop A10.2 - Fatigue Results Workshop Supplement

e. Fatigue Graph Results > Fatigue Sensitivity

06/24/2009 Introduction to Workbench Simulation Inventory #002590

… Workshop A10.2 - Fatigue Results Workshop Supplement

h. Similarly, select “Hysteresis 3” and, in the Details view, change

06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.2 – Solve and Review Results Workshop Supplement

10. Click on the “Solve” icon to initiate the fatigue analysis:

06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.2 - Review Fatigue Results Workshop Supplement

b. “Hysteresis 2” and “Hysteresis 3” show the cyclic stress-strain behavior

06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.2 – Re-run Fatigue Calculations Workshop Supplement

12. Click on the “Fatigue Tool” and

13. Re-run the fatigue calculations by

06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.2 - Review New Fatigue Results

14. Review “Damage”

No Mean Stress Correction SWT Mean Stress Correction

06/24/2009 Introduction to Workbench Simulation Inventory #002590

… Workshop A10.2 - Review New Fatigue Results

15. Select “Biaxiality Indication”

… Workshop A10.2 - Review New Fatigue Results

• Values of “0” correspond to uniaxial stress, “1” indicates a biaxial state of

06/24/2009 Introduction to Workbench Simulation Inventory #002590

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