You are on page 1of 46

Fatigue

analysis of
engineering
structures
Pres en te d by : Bharat h . S. O
(08 09 220 05 )
Nit es h Kum ar
(08 09 220 12 )

05/29/09 1
Introduction

 Fatigue- a process in which damage


accumulates due to the repetitive application
of loads that may be well below the yield
point.
 one popular view of fatigue in metals
 begin at an internal or surface flaw where the stresses
are concentrated, and consists initially of shear flow
along slip planes
 Over a number of cycles
this slip generates intrusions and extrusions that begin to
resemble a crack.

05/29/09 2
The main factors that contribute to fatigue
failures include:
 Number of load cycles experienced
 Range of stress experienced in each load cycle
 Mean stress experienced in each load cycle
 Presence of local stress concentrations

3
A fatigue analysis can be separated into 3 areas:
materials, analysis, and results evaluation.
 In a general sense, Fatigue Analysis has three
main methods, Strain Life, Stress Life, and
Fracture Mechanics; the first two being available
within the ANSYS Fatigue Module.
 The Strain Life approach is widely used at
present. Strain can be directly measured and has
been shown to be an excellent quantity for
characterizing low-cycle fatigue.

4
S-N curves

 most important empirical means of quantifying the


fatigue process

 constant cyclic stress amplitude S is applied to a


specimen and the number of loading cycles N until
the specimen fails is determined.
 Millions of cycles might be required to cause failure
at lower loading levels, so the abscissa in usually
plotted logarithmically 5
05/29/09
Analysis Decisions

 Common Decisions for Fatigue Analysis


 There are 5 common input decision topics upon
which your fatigue results are dependent
upon.These fatigue decisions are grouped into the
types listed below:
 • Fatigue Analysis Type
 • Loading Type
 • Mean Stress Effects
 • Multiaxial Stress Correction
 • Fatigue Modification Factor

05/29/09 6
Simplified Fatigue Analysis Decision Tree

05/29/09 7
Stress Life vs. Strain Life
 Within the ANSYS fatigue module, the first
decision that needs to be made in performing a
fatigue analysis is
Ø which type of fatigue analysis to perform?
Stress Life or Strain Life.?
 Stress Life is based on empirical S-N curves
and then modified by a variety of factors.
 Stain Life is based upon the Strain Life

Relation Equation where the Strain Life


Parameters are values for a particular
material that best fit the equation to
measured results.

05/29/09 8
Common Decisions to Both Types of
Fatigue Analysis
• Loading Type
• Mean Stress Effects
• Multiaxial Stress Correction
• Fatigue Modification Factor

Within Mean Stress Effects, the available


options are quite different…………………

05/29/09 9
05/29/09 10
Types of Cyclic Loading

vstatic stress, which is analyzed with calculations for


a single stress state….
qfatigue damage occurs when stress at a point
changes over time.

Øfour classes of fatigue loading, with the


ANSYS Fatigue Module currently supporting
the first three:
•
§ Constant amplitude, proportional loading
§ • Constant amplitude, non-proportional loading
§ • Non-constant amplitude, proportional loading
§ • Non-constant amplitude, non-proportional loading
05/29/09 11
Example of constant amplitude loading. In this case it is fully reversed
(+1 to -1) loading.

05/29/09 12
Mean Stress Correction
 Once you have made the decision on which type
of fatigue analysis to perform,
Stress Life or Strain Life,……..
and have determined your loading type, the
next decision is whether to apply a mean stress
correction.
 Cyclic fatigue properties of a material are often
obtained from completely reversed, constant
amplitude tests.

 Ifthe loading is other than fully reversed, a


mean stress exists and may be accounted for.
05/29/09 13
Mean Stress Corrections for
Stress Life
 For Stress Life, if experimental data at different
mean stresses or r-ratio’s exist, mean stress can be
accounted for directly through interpolation
between material curves.
 If experimental data is not available, several
empirical options may be chosen including Gerber,
Goodman and Soderberg theories which use static
material properties (yield stress, tensile strength)
along with S-N data to account for any mean stress.

05/29/09 14
Fatigue Modifications

 Value of Infinite Life


 Another available option when conducting a
variable amplitude fatigue analysis is the ability to
set the value used for infinite life.
 In constant amplitude loading, if the alternating
stress is lower than the lowest alternating stress
on the fatigue curve, the fatigue tool will use the
life at the last point.
 in non-constant amplitude loading, cycles with
very small alternating stresses may be present and
may incorrectly predict too much damage if the
number of the small stress cycles is high enough.

05/29/09 15
Fatigue Strength Factor

 Fatigue material property tests are usually


conducted under very specific and controlled
conditions.
 If the service part conditions differ from the as
tested conditions, modification factors can be
applied to try to account for the difference.
 Fatigue Strength Factor (Kf) reduces the fatigue
strength and must be less than one. Note that this
factor is applied to the alternating stress only and
does not affect the mean stress.

05/29/09 16
Loading Scale Factor

 Loading Scale Factor will scale all stresses,


both alternating and mean by the specified
value…
 This value may be parameterized
 Applying a scale factor is useful to avoid
having to solve the static model again to see
the effects of changing the magnitude of the
FEM loads.
 In addition, this factor may be useful to
convert a non-constant amplitude load history
data into the appropriate values (See
Connecting Rod Under Random Loading)……

05/29/09 17
 Thisconcludes the input decisions required to
perform either a Stress Life or a Strain Life
fatigue analysis. Once the fatigue calculation
has been performed, there are a variety of
results available that depend on the type of
fatigue analysis performed.

05/29/09 18
Types of Results

 Calculations
and results can be dependent
upon the type of fatigue analysis…

 Resultscan range from contour plots of a


specific result over the whole model to
information about the most damaged point in
the model (or the most damaged point in the
scope of the result).

05/29/09 19
 Results
that are common to both types of fatigue
analyses are listed below:
• Fatigue life
 • Fatigue damage at a specified design life
 • Fatigue factor of safety at a specified design life
 • Stress biaxiality
 • Fatigue sensitivity chart
 • Rainflow matrix output (Beta for Strain Life at 10.0)
 • Damage matrix output (Beta for Strain Life at 10.0)
 The results that are only available for Stress Life are:
 • Equivalent alternating stress
 The results that are only available for Strain Life are:
 • Hysteresis
05/29/09 20
Case studies
 1)Connecting Rod
Under Fully
Reversed Loading

 Here we have a
connecting rod
in a compressor
under fully
reversed loading
(load is applied,
removed, then
applied in the
opposite
05/29/09 21
 1.Import geometry and
apply boundary
conditions. Apply
loading corresponding
to the maximum
developed load of 1000
pounds.

 2. Insert fatigue tool.

 3.Specify fully
reversed loading to
create alternating
stress cycles.

05/29/09 22
 4.Specify that this is a stress-life fatigue
analysis. No mean stress theory needs to be
specified since no mean stress will exist (fully
reversed loading). Specify that Von-Mises
stress will be used to compare against fatigue
material data.

05/29/09 23
.Specify a
modification factor
of .8 since material
data represents a
polished specimen
and the in-service
component is cast.

05/29/09 24
 6.Perform stress and fatigue calculations
(Solve command in context menu).

 7.Plot factor of safety for a design life of


1,000,000 cycles

 8.Find the sensitivity of available life with


respect to loading. Specify a minimum base
load variation of 50% (an alternating stress of
500 lbs.) and a maximum base load variation
of 200% (an alternating stress of 2000 lbs.)

05/29/09 25
05/29/09 26
 9.Determine multiaxial stress state (uniaxial,
shear, biaxial, or mixed) at critical life
location by inserting “biaxiality indicator” into
fatigue tool. The stress state near the critical
location is not far from uniaxial (.1~.2), which
gives and added measure of confidence since
the material properties are uniaxial

05/29/09 27
05/29/09 28
Conclusion

 By the finite element analysis method and the


assistance of ANSYS software, It is able to analyze the
different components from varied aspects such as
fatigue and consequently save the time and the cost.
The way that defined loadings was effective on the
results achieved. So, they should fit as much as
possible the real conditions. As the fatigue analysis
requires some static analysis and to define the
boundary conditions closest to the real. Stress
concentration factors indicated the difference
between the real and the working condition. Relating
to the U650 connecting rod, the most critical node
numbered 46 and the number of allowable force
exertion cycles with the totally reverse loading were
gained 108 which increased by decreasing in stress
concentration factor.

05/29/09 29
MINIPROJECT
Fatigue analysis of a plate with a circular hole
 OBJECTIVE: To calculate Fatigue life of a Steel material
using Stress life approach.
Basic Terminology
A location is a node in the model for which fatigue
stresses are to be stored. It would typically choose
locations that represent points on the structure that
would be susceptible to fatigue damage.
 An event is a set of stress conditions that occur at
different times during a unique stress cycle.
 A loading is one of the stress conditions that is part
of an event.
 The alternating stress intensity is a measure of the
difference in stress state between any two loadings.

30
MODEL DESCRIPTION:
 1)Selectionof element type:Model is a Solid 42
element type with a dimension of rectangular
plate of 60x60 mm and a hole of 5mm radius with
thickness 5mm.Free Meshing with smart size 3 is
done on the model. E=2e5N/mm2,ν=0.3

 2)Loading: Since we have to do fatigue analysis,


we have to give repeated or fluctuating loads. So
here 1side tensile loads of -1000N on 1 ends of y
direction and the other end is fully constrained in
all directions and solved.

31
05/29/09 32
05/29/09 33
.

 3) Postprocessor:
Plot Von-mises
stresses and
displacement in
postprocessor
results. The plot
obtained is as
shown. This will be
saved as .rst file for
fatigue evaluation

05/29/09 34
Establish the Size, Fatigue Material
Properties, and Locations
Define the maximum number of stress
locations, events, and loadings.
 By default, it considers up to five nodal
locations, ten events, and three loadings within
an event.
 Command(s): FTSIZE
 GUI: Main Menu> General Postproc> Fatigue>
Size Settings

35
Define material fatigue properties.
 The S-N curve, a curve of alternating stress intensity
((Smax - Smin)/2) versus allowable number of cycles.
Command(s): FP, GUI: Main Menu> General
Postproc> Fatigue> Property Table> S-N Table

 The Sm-T curve, a curve of design stress-intensity


value versus temperature.
Command(s): FP, GUI: Main Menu> General
Postproc> Fatigue> Property Table> Sm_T Table

 Elastic-plastic
material parameters M and N (strain
hardening exponents).
Command(s): FP, GUI: Main Menu> General
Postproc> Fatigue> Property Table> Elas-plas Par
36
Ø Define stress locations and stress concentration
factors.
This option allows us to explicitly define a nodal
location of interest to our fatigue evaluation, define
stress concentration factors (SCFs) for that location,
and assign a short (20 character) title to that
location.
 Command(s): FL, GUI: Main Menu> General Postproc>
Fatigue> Stress Locations

Ø Storing Stresses
 Manually stored stresses
 Nodal stresses from Jobname.RST
 Stresses at a cross-section

37
Listing, Plotting, or Deleting Stored Stresses
 Listthe stored stresses per location, per event, per
loading, or per stress condition:
 Command(s): FSLIST, GUI: Main Menu> General
Postproc> Fatigue> Store Stresses> List Stresses

 Display a stress item as a function of loading number for


a particular location and event
 Command(s): FSPLOT, GUI: Main Menu> General
Postproc> Fatigue> Store Stresses> Plot Stresses

 Delete a stress condition stored for a particular location,


event, and loading:
 Command(s): FSDELE, GUI: Main Menu> General
Postproc> Fatigue> Store Stresses> Dele Stresses
38
 Delete all stresses at a particular location:
 Command(s): FL, GUI: Main Menu> General
Postproc> Fatigue> Stress Locations

 Delete all stresses for all loadings in a particular


event:
 Command(s): FE, GUI: Main Menu> General
Postproc> Fatigue> Erase Event Data

39
The following are the results obtained after
fatigue evaluation:

40
41
Location 1 Event 1 Node 578 Direct stress Sxy
42
Assigning Event Repetitions and Scale Factors
 This option assigns the number of occurrences to the
event numbers (for all loadings at all locations of the
event).
 Command(s): FE, GUI: Main Menu> General
Postproc> Fatigue> Assign Events

Activate the Fatigue Calculations


 This execute the fatigue calculations at a specified
location. The location is specified by either the
location number or the node itself.
Command(s): FTCALC, GUI: Main Menu> General
Postproc> Fatigue> Calculate Fatigue

43
Review the Results
 Fatigue calculation results are printed in the output.
 Command(s): *LIST, GUI: Utility Menu> List> Files>
Other> Jobname.OUT

 Ifwe have input an S-N curve, output is in the form


of a table of alternating stress intensities (listed in
decreasing order) with corresponding pairs of
event/loadings, as well as cycles used, cycles
allowed, temperature, and partial usage factor.

A convenient way to modify your events would be to


write all stored fatigue data on Jobname.FATG.

44
FS, NODE, NEV, NLOD, STITM, C1, C2, C3, C4, C5, C6

45
References:
 FUNDAMENTALS OF METAL FATIGUE ANALYSIS-JULIE.A.BENNANTINE
 ANSYS Structural Analysis Guide
 www.ansys.com
 Online ansys manual
 www.scribd.com
 Ansys verifcation manual
 Fatigue analysis of connecting rod of universal tractor
through finite element method (ANSYS)Journal of
Agricultural Technology 2008, V.4(2): 21-27
 Calculating and Displaying Fatigue Results, By Raymond
Browell Product Manager New Technologies,ANSYS, Inc.
 Fatigue Analysis of a Welded Assembly Using ANSYS
Workbench Environment Klaus-Dieter Schoenborn ANSYS
Service @ CADFEM GmbH, Germany
 ‘Fatigue’ David Roylance , Department of Materials Science
and Engineering, Massachusetts Institute of Technology
Cambridge, MA 02139 May 1, 2001

05/29/09 46

You might also like