Example4 FatigueTools WS01-SN

Introduction to Workbench Simulation 12.
Workshop A10.1
Fatigue: Stress-Life
06/24/2008 Workbench 12.0 Inventory #002590

© 2009 ANSYS, Inc. All rights reserved. ANSYS, Inc. Proprietary WSA10.1-1
Fatigue Module: Stress Life
Goals
Workshop Supplement
• Goal:
– In this workshop, our goal is to perform a Stress-Life analysis of the
connecting rod model (ConRod.x_t) shown here. Specifically, we will
analyze two load environments:
1) Constant Amplitude Load of 4500 N, Fully Reversed;
2) Random Load of 4500N.
06/24/2009 Introduction to Workbench Simulation Inventory #002590

Workshop A10.1 – Project Page

Workshop Supplement
• Start ANSYS Workbench 12.0. This brings you to a new Project Page
• From the “Units” menu verify:

- Project units are set to: Metric (m, kg, N, C, s, V, A)
- “Display Values in Project Units” is checked (on)

Workshop A10.1 - Preprocessing

Workshop Supplement
1. In the Toolbox, double-click on

“Static Structural” to create a
new analysis environment
1.
2.
2. RMB on the “Geometry” cell
and “Import Geometry”.
Browse to “ConRod.x_t”

Workshop A10.1 - Preprocessing

Workshop Supplement
3. Double click the “Model” cell to open the

Mechanical environment
3.
4. Set the working Unit System:

– Units > Metric (m, kg, N, s, V, A)
4.

. . . Workshop A10.1 - Preprocessing

Workshop Supplement
5. Apply loads to the model: a.

a. Select the connection rod surface shown
b. RMB > Insert > Force
c. Select Define By > Components and enter a
magnitude of - 4500N for the “Z Component”
b.
c.

. . . Workshop A10.1 - Preprocessing

Workshop Supplement
a.
6. Add supports to the model:
a. Select the bolt hole surfaces shown (HINT: use
CTRL+click to select both surfaces simultaneously!)
b. RMB > Insert > Cylindrical Support
c. Set Radial = Fixed, Axial = Free, Tangential = Free
d. Select the connecting rod surface shown
e. RMB > Insert > Fixed Support
d.
c.
b.

Workshop A10.1 - Solution / Results

Workshop Supplement
7. Solve the model:

• Click Solve
8. View the Results
a. Highlight the “Solution” branch
b. RMB > Insert > Deformation >Total
c. RMB > Insert > Stress > Equivalent (Von-Mises)
d. RMB > Evaluate All Results

Workshop A10.1 - Fatigue Tool

Workshop Supplement
9. Insert the Fatigue Tool:

a. Highlight the “Solution” branch
b. RMB > Insert > Fatigue > Fatigue Tool
10. Specify fatigue details:

a. Specify a Fatigue Strength Factor (Kf)
of 0.8 (material data represents a polished
specimen and the in-service component is
cast)
b. Loading > Type > Fully Reversed
(to create alternating stress cycles)
c. Options > Analysis Type > Stress-Life
(No mean stress theory needs to be
specified since no mean stress will exist
for fully reversed loading)
d. Specify that Von Mises stress will be used
to compare against fatigue material data
. . . Workshop A10.1 - Fatigue Tool

Workshop Supplement
11. Add results to the Fatigue Tool:

a. Highlight the “Fatigue Tool” branch
b. RMB > Insert > Safety Factor
c.
c. In the Details of the “Safety Factor” window,
set the “Design Life” to 1e6 cycles
d. RMB > Insert > Fatigue Sensitivity
e. In the Details of the “Fatigue Sensitivity”
window, specify the following:
Lower Variation: 50% (an alternating stress of
2250N)
Upper Variation: 200% (an alternating stress
of 9000N). e.
f. RMB > Insert > Biaxiality Indication
12. Click Solve to evaluate these results

Workshop A10.1 - Results

Workshop Supplement
• Safety Factor

. . . Workshop A10.1 - Results

Workshop Supplement
13. Highlight and plot the “Fatigue Sensitivity” result for a minimum
base load variation of 50% and a maximum base load variation of
200%.


Workshop Supplement
14. Find the sensitivity of available life with respect to loading for a
maximum base load variation of 400%.
• Note: must re-solve to obtain the new Fatigue Sensitivity results.


Workshop Supplement
15. Highlight and plot the “Biaxiality Indication” result

• Recall, a biaxiality of zero corresponds to uniaxial stress, a value of –1 corresponds to pure shear,
and a value of 1 corresponds to a pure biaxial state

Workshop A10.1 - Fatigue Tool

Workshop Supplement
16. Analyze a random load of 4500N:

• Note: Assume that we have strain gauge results that were
collected experimentally from the component and that we know
that a strain gauge reading of 200 corresponds to an applied load
of 4500N
a. Highlight the solution branch
b. RMB > Insert > Fatigue > Fatigue Tool
a.
17. Specify fatigue details:
a. Specify a Fatigue Strength Factor (Kf) of 0.8
(material data represents a polished specimen b.
and the in-service component is cast)
b. Change Loading > Type to History Data
c. Click on “History Data Location” to open
“SAEBracketHistory.dat” , which contains
the strain gauge results over time c.


Workshop Supplement
d. Define the scale factor to be .005 (we must

normalize the load history so that the FEM
load matches the scale factors in the load
history file)
1 FEM load 1000lbs 1 FEM load
0.005
1000lbs 200 straingage 200 straingage
e. Specify Goodman theory to account for

mean-stress effects
f. Specify that a signed Von Mises stress will be
used to compare against fatigue material data
(use signed since Goodman theory treats
negative and positive mean stresses
differently)
g. Specify a bin size of 32 (Rainflow and
Damage matrices will be of dimension 32x32)


Workshop Supplement
18. Add results to the Fatigue Tool 2:

a. RMB > Insert > Life
b. RMB > Insert > Safety Factor
c. Set the Design Life to 1000 blocks
d. RMB > Insert > Fatigue Sensitivity
e. In the Details of “Fatigue Sensitivity”
window, specify:
• Lower Variation of 50% (an alternating stress
of 2250N)
• Upper variation of 200% (an alternating
stress of 9000N)
f. RMB > Insert > Biaxiality Indication
g. RMB > Insert > Rainflow Matrix
h. RMB > Insert > Damage Matrix
i. From the Details of “Damage Matrix”
window, set the Design Life to 1000 blocks
19. Click on Solve

Workshop A10.1 - Results

Workshop Supplement
20. View Results:

a. Highlight and plot the “Life” result


Workshop Supplement
b. Highlight and plot the “Safety Factor” result for a design life of
1000 blocks
If the loading history corresponded to the

loading experienced by the part over a
months time, the damage and SF will be
at a design life of 1000 months.
Note that although a life of only 77
loading blocks is calculated, the needed
scale factor (since SF @ 1000 = 0.60) is
only 0.60 to reach a life of 1000 blocks.
Note, the “scale factor” is the scale

factor for the loading to make it meet
the life of 1000 months.


Workshop Supplement
c. Highlight and plot the “Fatigue Sensitivity” result for a minimum base
load variation of 50% and a maximum base load variation of 200%.


Workshop Supplement
d. Highlight and plot the “Biaxiality Indication” result


Workshop Supplement
e. Highlight and plot the “Rainflow Matrix” result
The rainflow matrix shows that

the majority of the cycle Counts
are for low mean stress (Mean)
and low stress amplitude
(Range)


Workshop Supplement
f. Highlight and plot the “Damage Matrix” result
Although, from the previous slide, one

saw that most of the counts were for
the low mean and low range bins,
these do not cause the most damage
at the critical location, as shown in this
damage matrix. Instead, the 'medium'
stress amplitude cycles cause the
most damage at the critical location.


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Introduction to Workbench Simulation 12.

06/24/2008 Workbench 12.0 Inventory #002590

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

Workshop A10.1 – Project Page

• From the “Units” menu verify:

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

Workshop A10.1 - Preprocessing

1. In the Toolbox, double-click on

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

Workshop A10.1 - Preprocessing

3. Double click the “Model” cell to open the

4. Set the working Unit System:

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

. . . Workshop A10.1 - Preprocessing

5. Apply loads to the model: a.

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

. . . Workshop A10.1 - Preprocessing

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

Workshop A10.1 - Solution / Results

7. Solve the model:

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

Workshop A10.1 - Fatigue Tool

9. Insert the Fatigue Tool:

10. Specify fatigue details:

. . . Workshop A10.1 - Fatigue Tool

11. Add results to the Fatigue Tool:

12. Click Solve to evaluate these results

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

Workshop A10.1 - Results

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

. . . Workshop A10.1 - Results

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

. . . Workshop A10.1 - Results

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

. . . Workshop A10.1 - Results

15. Highlight and plot the “Biaxiality Indication” result

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

Workshop A10.1 - Fatigue Tool

16. Analyze a random load of 4500N:

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

. . . Workshop A10.1 - Fatigue Tool

d. Define the scale factor to be .005 (we must

e. Specify Goodman theory to account for

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

. . . Workshop A10.1 - Fatigue Tool

18. Add results to the Fatigue Tool 2:

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

Workshop A10.1 - Results

20. View Results:

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

. . . Workshop A10.1 - Results

If the loading history corresponded to the

Note, the “scale factor” is the scale

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

. . . Workshop A10.1 - Results

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

. . . Workshop A10.1 - Results

d. Highlight and plot the “Biaxiality Indication” result

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