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COSMOSWorks Professional Training


COSMOSWorks 2007

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for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Six types of analysis


Frequency
Frequency

Fatigue
Fatigue

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Buckling
Buckling

Optimization

Thermal
Thermal

Drop
Drop Test
Test

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Frequency Analysis

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Frequency Analysis

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What if loads are changing very slowly with


time ? Can we still use the assumption of
Static analysis ?
Yes, if the frequency of the applied load is
significantly lower than the first natural
frequency of the structure. If not, a vibration
analysis is required to check if the structure is
likely to resonate.

What do we get from Frequency analysis ?


Frequency values and deformation modeshapes
Cannot get actual values of displacements
only obtained deformation mode
Actual values of displacements depends on
amplitude of imposed loads and damping

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Lesson 1
Frequency Analysis of a Tuning Fork

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Lesson 1 Results

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Exercise 1

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Lesson 2
Frequency Analysis of a Blower Fan

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Lesson 2 Topics

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Frequency analysis with loads


Loads affect the natural frequency
Compressive loads decrease resonant frequencies and tensile
loads increase. Example: changing the tension on a violin string
the increasing the tension will increase frequency.
Use the Direct Sparse solver. If Solver option is set to
Automatic, then Direct Sparse solver will be used when loads are
defined for a frequency study

Three studies
Frequency of blade when there is no rotation
Frequency of blade when rotating at 3000 rpm
Using Design Scenarios to get frequencies of
blade when rotating at various speeds
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Lesson 2 Results

No rotation

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Rotation Speed 300 rpm

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Lesson 2 Results

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Sensitivity Study Design Scenarios

With increasing rpm the blades become stiffer.


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Exercise 2

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Frequency Analysis of an impeller rotating at 20000 rpm


Mixed Meshing
Bonded contact sets between Solid and Shell

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Lesson 3
Buckling analysis of a stool

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Lesson 3 Topics

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A small increase in load causes an abrupt large increase in deformation


Large compressive force
Associated with slender components subjected to axial compressive force
Buckling Load Factor =

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Lesson 3 Results

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Lesson 3 Results

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Buckling shapes
Buckling modal shape #1

Buckling modal shape #2

Look at the values of the displacements. Why are these values so large?
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Exercise 3

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Buckling analysis of a lamp shade


Compare the buckling load factors for two configurations

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Thermal analysis

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Thermal analysis analogy to stress analysis

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Thermal analysis - Conduction

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Heat Flux = - Thermal_Conductivity * Area * Temperature_gradient

Thot

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Tcold

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Thermal conductivity of materials

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Thermal Analysis - Convection

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Heat flux = Convection_coefficient * Area * Difference in Temperature

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Convection coefficient

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Thermal Analysis - Radiation

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Thermal energy emitted by bodies in the form of electromagnetic


waves because of their temperature

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Types of Radiation Surface to ambient

Stefan-Boltzmann constant

Surfacetemperature

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Ambienttemperature

= 5.67E-8 W/m2K4
Emissivity of the radiating surface (between 0 and 1)
Aluminum (polished) 0.04-0.06
Copper (commercial) 0.07
Steel (polished) 0.52-0.56
Steel (rough) 0.95-0.98
Porcelain 0.92
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Types of Radiation Surface to surface

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Radiation heat transfer between two surfaces


also depends on:
shape of faces
relative orientation of faces
distance between the faces
Radiation View Factor The fraction of thermal energy leaving the surface of
object 1 and reaching the surface of object 2, determined entirely from
geometrical considerations. It is the fraction of object 2 visible from the surface
of object 1.
A multiplier to the previous equation that takes above factors into account and
calculated internally by COSMOS. It is unitless and ranges between 0 and 1.
A concave face can radiate to itself; Planar and convex faces do not radiate to
themselves. Such effects are automatically considered.
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Lesson 4
Thermal analysis of a spot light assembly

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Lesson 4 Topics

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Steady state heat transfer including conduction,


convection and radiation
Conductivity of materials applied by materials properties
of solids
Convection is applied to the surfaces exposed to the
atmosphere
Radiation between the bulb and lamp-surfaces
Bulb generates 100 Watts of heat power

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Lesson 4 Results

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Results temperature distribution

Notice small effect on the temperature of the reflector.


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Lesson 4 Results

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Heat flux distribution

Notice heat flux concentrations near the corners.


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Exercise 4

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Thermal analysis of a cup

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Lesson 5
Thermal Analysis of a Microchip Assembly

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Lesson 5 Topics

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Microchip generates 25 Watts of heat power


Connectors are insulated
Four studies
STUDY 1: Steady state heat transfer
STUDY 2: Transient thermal analysis
Study how the temperature increases in the first 300 seconds after power is first turned on

STUDY 3: Transient thermal analysis


Heat-power is increased gradually in the first 30 seconds

STUDY 4: Transient thermal analysis with thermostat


Heat-power is controlled (turned on and off) by a thermostat in order to prevent the microchip from overheating

New topics:
Thermal resistance
Thermostat

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Thermal Resistance

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Resistance to heat flow at the junction of two


components - Tiny air gaps will always exist between
the two contacting surfaces due to their roughness

Thermal Resistance depends on:


1. Surface Flatness
2. Roughness of surfaces
3. Contact-force between surfaces
4. Thermal interface material (e.g., thermal
grease, elastomer, adhesive, etc.)

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Typical Thermal resistance values


Dry Joint

2.9 C/W

Thermal grease (0.003 in gap)

0.9 C/W

Elastomer (0.010 in thick)

1.8 C/W

Adhesive (0.009 in thick)

2.7 C/W
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Thermostat

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Heat-power or flux condition is turned on or off based on the


temperature at the specified vertex
Obtained results will slightly overshoot the target temperature

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Lesson 5 Results

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STUDY 1: Steady state thermal analysis

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Lesson 5 Results

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STUDY 2: Transient thermal analysis

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Lesson 5 Results

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STUDY 3: Transient thermal analysis after heat-power is turned on and then turned off

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Lesson 5 Results

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STUDY 4: Transient thermal analysis with thermostat

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Exercise 5

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Thermal analysis of coffee pot

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Lesson 6
Thermal Stress Analysis of a Microchip Testing Device

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Lesson 6 Topics

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Study 1 Steady state thermal analysis


Study 2 Static study to get deformation due thermal
effects
Microchip generates heat power of 0.005 BTU/s
Face of acrylic gasket is kept at 200 F
Ambient temperature is 77 F

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Lesson 6 Results

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Thermal analysis - results


Temperature section view

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Heat fluxes vector plot

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Lesson 6 Results

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Stress analysis results


Von Mises stresses

Energy norm error plot

Larges errors occur near the sharp re-entrant edge. Why?


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Lesson 6 Results

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Stress Analysis with Bolt Connectors - Results

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Exercise 6

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Thermal analysis and stress analysis of a gas tank

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Drop Test Analysis

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Drop test analysis

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Evaluate the effect of the impact of a part or an assembly


with a rigid or flexible planar surface
Calculates impact and gravity loads automatically. No other
loads or restraints are allowed
Equlibrium of forces:
Inertial_forces + Elastic_forces = Gravitational_force + Impact_force
(Damping is ignored)

Dynamic problem forces and displacements are changing


with time
Explicit time integration to solve the problem
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Input and results in drop test

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Input:

Drop height or Velocity at impact


Gravity
Orientation
Observation time - For how long after impact should one observe or
capture the solution?
Stiffness of the impacted surface (wall)

Results:
Observe displacements and stresses at various times
Contact force at surface of impact

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Lesson 7
Drop Test Analysis of a Camera

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Lesson 7 Topics

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Goals

Drop test analysis

Analysis Basics
Analysis Setup
Post-processing options for
drop test analysis

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Key Results

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Rigid target Von Mises stresses

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Key Results

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Rigid target stress time history graph

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Key Results

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Soft target Von Mises stresses

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Key Results

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Vertex 1 resultant acceleration history


Rigid target

Soft target

Soft target reduces the acceleration peaks.


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Exercise 7

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Drop test of a clip

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Design optimization

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Design optimization

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Find the best design by changing geometry


Objective. Defines the best design. For example, minimum material.
Design Variables. Select the dimensions that can change and set
their ranges. For example, the diameter of a hole can vary from 0.5
to 1.0 while the extrusion of a sketch can vary from 2.0 to 3.0.
Constraints. Set the conditions that the optimum design must satisfy.
For example, stresses should not exceed certain values and the
natural frequency should be in a specified range.

Before creating an optimization study, you should create at


least one study (Static or Frequency or Buckling or Thermal)
that you will use to define the objective function and
constraints.
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Design optimization - objective

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The objective defines the goal of the


optimization process
You can specify only one objective in an
optimization study

Minimize volume or mass


For assemblies with different materials, the
optimum design that minimizes volume will be
different from the optimum design that
minimizes mass

Maximize buckling load factor


Maximize or Minimize resonance
frequency
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Design optimization design variables

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Design variables are the changeable dimensions of the model.


Any dimension can be defined as a design variable. For each
design variable, you need to specify the lower and upper bounds
as well as a tolerance.

Make sure that design variables do not contradict with any


relations specified in the model

Diameter of hole is increased

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Design optimization - constraints

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Constraints - The conditions that the optimized design must


satisfy
A constraint is associated with the initial study
For static studies. Nodal or element stresses, strains, or
displacements
For buckling studies. First through tenth buckling load
factors
For frequency studies. First through tenth resonant
frequencies
For thermal studies. Temperatures, temperature gradients,
or heat fluxes
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Lesson 8
Optimization Analysis of a Press Frame Assembly

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Lesson 8 Topics

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Find the best design that satisfies the following conditions:


Maximum stress is less than 15 ksi
Maximum deformation is less than 0.04 in
Smallest natural frequency is more than 80 Hz
Design variables are:
Height of side plate (vary between 2 inches to 4 inches)
Cut-out of legs (Vary between 4 inches to 10 inches)
Length of back-plate (Vary between 6 inches and 15 inches)

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Lesson 8 Basics

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Optimization procedure
Step 1.
Define the
objective
Step 2.
Specify the design
variables
Step 3.
Specify the
constrains

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Key Results

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Optimization procedure Design results

Before Optimization
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After Optimization

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Key Results

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Optimized Design Results


Von Mises stresses

VM . max 14.6 ksi VM .Opt .Limit 15 ksi

Resultant Displacements

u Re s.Max 0.02 in 0.04 in

Fundamental frequency

80 Hz 1.Max 82.38 Hz 150 Hz

Mass is minimized, all constrains have been satisfied


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Key Results

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How did our objective converge?

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Exercise 8

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Optimization of a cantilever bracket

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Fatigue analysis

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Why Consider Fatigue?

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Traditionally designers consider the


ultimate strength of their
components. Design for Strength
But in-service load is rarely static in
nature; there is usually a cyclical
variation.
Designers should use a Design for
Life rather than a Design for
Strength approach.

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Fatigue Design Criteria

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Infinite-Life Design
Unlimited safety, elastic stress concentrations, expensive, very limited
applicability
Safe-Life Design
No cracks on predetermined # of cycles, limited # of high stress (strain)
cycles
(pressure vessels, jet engines, landing gears, gun tubes)
Used where regular inspections are difficult
Fail-Safe Design
Cracks present but do not lead to failure before their detection and repair
Failure of component does not cause failure of the structure
Decrease in weight and cost
Sophisticated inspections & Testing
(wings, fuselage, multi-engine airplane engines)
Damage-Tolerant Design
Cracks present but do not lead to failure before their detection and repair
(fracture mechanics and other tools to predicts the crack behaviour)
Sophisticated inspections & Testing
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High Cycle fatigue (HCF) Vs Low Cycle Fatigue (LCF)


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High Cycle

Low Cycle

Low Stress

High Stress

> 10,000 cycles

10-10,000 Cycles

Stress Life (S-N) Method valid


Strain-Life Methods appropriate

Strain-Life (E-N) Methods suitable

Total Life Predictions Possible

Crack Initiation Dominant mode

No plastic deformation

Shows high plastic deformation

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High Cycle fatigue (HCF); Low Cycle Fatigue (LCF)


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Typically S-N curve is represented on a Log-log scale


Analysis of High Cycle Fatigue (more than 1000 cycles) in
COSMOSWorks
Infinite life
Part 1

Part 2

Part 3

Stress amplitude, Sa (ksi)

Su

Fatigue S-N curve


S103
Sy

Se

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Number of cycles, N

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Stress definitions
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S alt
S max
S mean
S min

R0
S mean 0

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Stress ratio:

S min
S max

Mean stress:

S max S min 1

Alternating stress:

2
S max S min 1
2

R 1
S mean 0

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S-N Curve

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Failure under repeated loading cycles


Maximum stress is smaller than yield strength of material
Material Testing Several test
specimens are subjected to
repeated cyclic loads until
failure.
S-N Curve Plot of number of
cycles (N) to failure for different
stress levels (S)

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S-N Curves in COSMOSWorks

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Materials in the
library with predefined SN Curves
are marked with
(SN)

Enter or Import tabular data


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S-N Curves in COSMOSWorks

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ASME Reference Curves

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Miners Rule (Theory of accumulative damage)

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If a structure is
subjected to L1 cycles
at S1 and L2 cycles at
S2, will the life of the
structure be
exhausted?

Stress
Amplitude
L1
S1
L2
S2
N1

N2
Number of cycles

Failure due to fatigue occurs when the damage factor reaches 1.


Assumptions: ignores load sequence and damage accumulation time rate
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Effect of Mean Stress


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Stress amplitude, Sa

Tensile mean stress is


decreases fatigue life
sm> 0

0
sm= 0

sm< 0

Most SN curves are


produced under zero mean
stress

Stress amplitude, logSa


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time

Compressive mean stress


is beneficial or has negligible
effect on the fatigue
durability.

Negative Mean Stress


Zero Mean Stress
Positive Mean Stress
No. of cycles, logN

2*106

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Mean Stress Correction


S alt

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Ductile Materials Gerber method

Sfatigue, alt

Brittle Materials Goodman method


Soderberg method conservative in tension
Goodman

1
Gerber

S alt
S fatigue, alt

0.5

Soderberg

-0.5
0
Any combination of compressive meanstress and alternating-stress to the left
of the curve is deemed safe
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0.5
S mean S yield

S mean
S ultimate

S mean S ultimate
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Types of Loading

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Constant
Amplitude
Loading

Variable
Amplitude
Loading
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Fatigue Prediction in COSMOSWorks

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Define one or more Static Structural studies


Specify or define a SN curve for each material
Multiple materials can have their own SN curve.

Solve for displacement and stress

Define a Fatigue Study


Specify as either a constant or variable amplitude study
Define events based on previously solved studies
Define a loading ratio

Set Study Properties for:

Event Interaction
Mean Stress Correction
Alternating Stress Calculation method
Fatigue Strength Reduction Factor

Determine if you need results on the surface or through the entire volume

Solve and Review results


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Fatigue results

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Life plot:

Number of cycles to cause a fatigue failure.

Damage plot:

Amount of life consumed by fatigue events.

Factor of safety:

FOS<1 (structure is damaged), FOS>1 (structure has life left)

Biaxiality indicator:

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Distribution of

1
2

(3 is ignored)

83

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Lesson 9
Fatigue Analysis of a Pressure Vessel

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Lesson 9 Topics

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One million cycles of pressure load of 1000 psi


and heat-flux of 1500 Watt/sq m
First perform thermal study to get temperature
distribution
Next perform static study to get stress
distribution due to temperature difference
Perform another static study to get stress
distribution due to internal pressure of 1000 psi
Create a fatigue study that will take as input the
two static studies

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Lesson 9 Results

Areas with Damage Factor greater than 1


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All life has been take up vessel fails


86

Exercise 9

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Fatigue analysis of a basketball rim

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Lesson 10
Fatigue Analysis of an automobile suspension

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Lesson 10 Topics

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Vehicle moving at a constant


speed on a banked road
Variable amplitude loading

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Lesson 10 Results

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90

Lesson 10 Results

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Most of the damage is not caused by the highest mean stress


cycles (they do not occur as frequently), but rather it is caused
by the intermediate mean stress cycles.

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91

Modifying Factors
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Several factors have to be taken into account while using the


empirical S-N curve for simulation of real-life model:
Corrosive environment kc
Surface conditions ks
Size factor kl
Mode of loading km
Temperature factor kt
Reliability factor kr
Notch effects kf
Fretting conditions kfret

Fatigue Strength Reduction Factor =kc* ks* kl* km* kt* kr* kf* kfret
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Modifying Factors Corrosion conditions


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Long life (typically high cycle) fatigue issue

kc = 0.1 1
(reference value is
fatigue strength in air
environment)

Reproduced from Metal Fatigue in


Engineering by Stephens R.I. et. all,
Copyright @ 2001 John Wiley & Sons, Inc.
This material is reproduced with permission
of John Wiley & Sons, Inc.
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Modifying Factors Surface condition


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Due to scratches, pits and machining marks on the surface


Fatigue originates on the surface!

ks = 0.1 - 1

Reproduced from Metal Fatigue in


Engineering by Stephens R.I. et. all,
Copyright @ 2001 John Wiley & Sons, Inc.
This material is reproduced with permission
of John Wiley & Sons, Inc.
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94

Modifying Factors Size effect


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Size of the test specimen is not the same as the real-life model.
Voids and defects in material will increase as size of the model
increases.
For models with circular cross-sections:
Diameter less than 0.3in (8mm)

kl = 1

Diameter between 0.3in (8mm) and


10in (25mm)

kl = 0.869 *(diameter inch)-0.097


(approx. 0.7 0.8)

For non-circular model determine effective diameter by equating


the volume of material stressed at and above 95% of the
maximum stress to the same volume in the rotating-bending
95
specimen.
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Modifying Factors Loading condition


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S - N curves are different for different types of tests.

120

Stress
(ksi)

70

Bending
Axial

50

Torsion

Su ,axial
0.75 0.9
Su , bending
(Su Fatigue limit )

30
10

10

10

10

10

Number of cycles, Log(N)


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96

Modifying Factors High Temperature


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High temperature reduces the material fatigue resistance.

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Reproduced from Metal Fatigue in Engineering by Stephens R.I. et.


all, Copyright @ 2001 John Wiley & Sons, Inc. This material is
reproduced with permission of John Wiley & Sons, Inc.

97

Modifying Factors Low Temperature


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Low temperature increases the material fatigue resistance.


IMPORTANT!
The resistance of the
material against the
growth of the cracks
decreases.
(crucial in Damage
Tolerant Design
methodology)
Not recommended to rely
on this phenomenon!

2007 SolidWorks Corp. Confidential.

Reproduced from Metal Fatigue in Engineering by Stephens R.I. et.


all, Copyright @ 2001 John Wiley & Sons, Inc. This material is
reproduced with permission of John Wiley & Sons, Inc.

98

Modifying Factors Reliability factor


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Account for the scatter in the test-data in S-N curve fitting.


Reliability factor between 0.52 1.00 from handbooks
Desired
probability of
failure P in
engineering is
generally smaller
than 0.01.

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99

Modifying Factors Notch effects


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Fatigue notch factor effect kf depends on the stress


concentration factor Kt, geometry (fillet or notch) and material:

K t 1

k f 1
a

r is radius of fillet or notch


a is material constant

300

0.001
Ultimate Strength in psi
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1.8

100

Modifying Factors Fretting


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Relative motion of two connected components (bolted


connections etc.) causes surface debris promoting surface
cracks.

Reproduced from Metal Fatigue in Engineering by Stephens R.I. et.


all, Copyright @ 2001 John Wiley & Sons, Inc. This material is
reproduced with permission of John Wiley & Sons, Inc.

Requires experience, reduction in the fatigue strength may


reach up to 90%!
Micro-motion is enough to cause fretting surface cracks.
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101

Closing comments for fatigue


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Primary purpose of studying fatigue is to understand why


failure occur
Simulation approaches do not yield absolutely precise results
Results should be taken as a guide for designing against
fatigue failure
Testing is necessary

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Thank You

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Practice lessons and exercises in the training manual


Where to get help ?

Online Help
Local SolidWorks reseller
Customer Portal / Knowledge Base
Technical Support 31-309-2800 or cosmossupport@solidworks.com
COSMOS Companion (Every Wednesday at 11:00 AM EST)
http://www.cosmosm.com/pages/news/COSMOS_Companion.html

2007 SolidWorks Corp. Confidential.

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