Fatigue Calculations | Fatigue (Material) | Structural Load

# BASIC-Module

The Program (Fatigue Life Information using Finite Elements) makes it possible to calculate the fatigue life of components under dynamic loading. The fatigue life can be calculated in the classic way based on nominal stress (without using finite elements) or by way of local strain approach using notch factors in the usual manner. S-N Curves for the nominal stress method can be created for iron materials. If you wish to use the local concept, the program provides various possibilities for creating cyclic material data (Uniform Material Law etc.). The data required for a fatigue life calculation is stored in a data base. This data base can be extended by the user. diagram 2: load histoy from a measurement The program can generate standard collectives. This is a support for the user should he not have his own measured data.

is available for Windows 95, 98 and Windows NT. A close link to FE-Programs MSC/NASTRAN, SAMCEF and WTP2000 has been achieved.

only contains the signal parts relevant to the damage (diagram 3). shows the results of the damage calculation in the rainflow matrix in colour. The critical signal parts are therefore immediately obvious. If the local concept is used, the stress- strain paths from the rainflow matrix are calculated and shown in a graph (diagram 4). The total damage is obtained by adding

Fatigue Life Calculation without FEM
A fatigue life calculation can be carried out by the classic methods - nominal stress concept and local concept. As well as the other material data required for each type of concept, i.e. for the nominal stress concept: stress S-N curves and mean stress sensitivity, and for the local concept: cyclic stress-strain curves, strain e-N curves and damage parameter curves according to Smith, Watson und Topper, the component loading is provided. This is made possible because loads are fixed by progressive collectives (mean-load, load amplitude and number). These fixed loads can be either entered manually or taken from the program`s generator.

Diagram 3: Rainflow matrix of the stress-time history. The height of the column shows the number as a percent, the colour shows the damage. together the damage proportions accumulation hypothesis). (linear damage

Program uses the Rainflow method as is The usual when calculating fatigue life. The rainflow matrix

s
Masing

hysteresis loop

ε
hysteresis loop

cyclic
hysteresis loop

Diagram 1: progressive collective with standard Gauss divisions, created by the collectives generator.

Diagram 4: from the stress-strain path calculated from the rainflow matrix

Steinbeis TC New Technologies in Traffic Engineering, Prittwitzstr. 10, 89075 Ulm, Tel.: +49 / 7325 3306

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the rainflow matrix. If the calculation is done according to the local concept. In the case of local concept. elementary. The direction of the standard load must correspond to the actual force F(t). Prittwitzstr. 10. there is an actual stressstrain curve.BASIC-Module With the nominal stress method. Diagram 5 shows these possible hypotheses. Diagram 5: various types of nominal stress S-N curves which can be used in . The damage calculation is assisted by a damage parameter curve as suggested by Smith.: +49 / 7325 3306 2 . including plastic deformation can be calculated using Neuber's rule. is sufficient to calculate the parts of the load relevant to the damage (the closed hysteresis loops) diagram 6: cyclic stabilized material propoerties Diagram 6: cyclic stress-strain curve and masing pattern. For this purpose the state of stress is calculated in a structure which is subjected to a standard load Fo. If. Watson und Topper (diagram 7). Liu and Zenner). the cyclic stressstrain-path and the material memory (masing effect) will be taken into consideration (diagram Therefore the stress reduction due to plastic changing shape and hysteresis loops which damage the material are included. One important difference however. is that a static FE calculation is used to ascertain the stress within the component. for example. Diagram 7: damage parameter S-N curve according to Smith. This means that the actual stress path for each node. The elastic stress for each load F(t) can then be calculated in a linear way corresponding to the quotients F(t)/Fo. Tel. modified according to Haibach. a force F(t) exists as shown in diagram 1. Fatigue Life Calculation Combined with FEM The fatigue life calculation is carried out in a similar way to that described above. then the stress within a component can be calculated for any required moment. Steinbeis TC New Technologies in Traffic Engineering. 89075 Ulm. Watson und Topper The result from the rainflow count of the outer loading history. various hypotheses can be used to consider the fatigue limit (original.

the user can select nodes for the fatigue life calculation according to various criteria. Prittwitzstr. a helpful stress-time function can be ascertained for each selected node for which damage can be determined. 89075 Ulm. you will require suitable S-N curves or data describing the damage. can be shown by the FE-program in colour. not all the nodes of a structure are endangered . This data base is constructed so that the user can add his own data to it. so that MSC/NASTRAN macros are supplied with data can be transferred from MSC/NASTRAN for Windows.the damage usually begins on the surface . the number of nodes to be examined can be substantially reduced and the calculation time shortened accordingly.e. Diagram 9: Structure of the data base Steinbeis TC New Technologies in Traffic Engineering. Tel. Diagram 8 shows an example for a component for which a fatigue life calculation was carried out. i. Material Data If you wish to carry out a fatigue life calculation. The lever seen here is loaded by 2 groups of forces which have an effect on the structure. A separate colour is used for each different range f damage (diagram 8).: +49 / 7325 3306 3 . There is also a link between the FE programs WTP2000 and SAMCEF. A fatigue life calculation is carried out based on a static FE calculation with a standard load for each group of forces. By doing this. The damage to the lever which is subjected to time varying forces is shown in colour (Iso_Lifes = lines of equal damage) for each node of the FE structure. By doing this. These can then be added together for a total damage sum. one after the other. The MSC/NASTRAN user-interface is available for all data transactions between und MSC/NASTRAN. generally speaking. Users of MSC/NASTRAN will therefore have no difficulties using this program. comes with a data base containing this information for some of the engineering materials commonly used. 10. The results from . the damage for each individual node.BASIC-Module Diagram 8: Result of a fatigue life calculation using in conjunction with MSC/NASTRAN. Because. The stress results. Links to FE programs other than those mentioned here are possible since the interfaces in are available as ASCII files and well documented. which are kept static according to the time varying force group having an effect. are re-calculated in a linear way and corrected by Neuber's rule in a non-linear way. We are always willing to give further assistance if particular material data is required which is not included in the data base (diagram 9) . The damge calculation results are saved separately for each individual force group.

Tel. the classic calculation methods will not work. (Diagram 11. For this reason we offer 3 seminars each year to introduce you to the basics. Only then can the results be interpreted correctly. This generates SN curves based on static material data and information on the component.: +49 / 7325 3306 4 . In this case the multiaxial supplement should be used. Courses.as well as the widely acceptedUniform Material Law.: +49 / 7325 4992.) Prices and Conditions Basic-Module 6000 DM Up-grades required for working with the Basic Module (separate brochures are available): Gear wheels and bearings Multiaxial 8000 DM 4000 DM Discounts available: Research and Lecturers 50%. Diagram 10 shows which possibilities are available.BASIC-Module In many cases it helps if the fatigue life data is created according to static characteristic material values. Diagram 10: Input dialog to generate cyclic material data (local concept) A S-N curve generator is available for the nominal stress concept and the notch stress concept.com Fatigue Life Calculation of Gear Wheels The fatigue life of gear wheels and bearings is calculated in a similar way to general engineering components.1. This has been available since 1.0 and subsequent versions. Steinbeis TC New Technologies in Traffic Engineering. E-mail guenterwillmerding@compuserve. Multiple licences can be obtained with specific permission Free user service is available for one year after purchase of the program. considerable and much longer than when using the Basic Module. 10 89075 Ulm Tel. User Service If the program is to be used effectively. 10. Diagram 11: Input dialog for the S-N curve generator for the nominal stress concept Contact: Steinbeis Transfer Center "New Technologies in Traffic Engineering" Prittwitzstr. The calculation process is the same as in the Basic-Module. it is important that the user is acquainted with all aspects of fatigue strength under variable stress amplitude. however. It should only be used when the principal stress directions change a great deal.1999 with Version 2. Therefore the user will very soon get to grips with this program. Fax. Multiaxial Calculation If a structure is subjected to several loads which are out of sync and not proportional.: +49 / 7325 3306 oder +49 / 7325 919471.0 and subsequent versions. A module for this calculation has therefore been created which is integrated in the user-interface of winLIFE Version 2. 89075 Ulm. offers several possibilities for the local concept . The calculation time is. Prittwitzstr.