FEMFAT50

FEMFAT Version 5.0 News

Christian Gaier

April 2011

1

ECS / Disclosure or duplication without consent is prohibited

FEMFAT 5.0 Top Features

Pore InfluenceFEMFAT SPECTRALModernized GUI

3D-PresentationBREAK for MAX

Extended WELD

Database2


FEMFAT 5.0 More Features

Methods

BASIC: PLAST-module extended for Mises-stress

BASIC: Definition of cutting plane angle

BASIC: New default setting Scaled normal stress for all materials except gray cast iron

BASIC & MAX: Parameters of technological size influence can be defined in userdefparam.dbs

WELD: Sensitivity analysis for process influences of welding seams

SPOT force based: Diameter and material from connected sheets

VISUALIZER

Display groups of weld seams of same type

Set color and line thickness for welding seams

3


FEMFAT 5.0 Even more Features

Interfaces

ABAQUS ODB interface: Import of increment 0(e.g. from POST OUTPUT)

ABAQUS ODB interface: Import of shell thicknesses from forming simulation

Mapping of FEMFAT nodal results to elements and export to HyperMesh

Output rainflow matrix data as CSV-file

Handling

Definition of path to WELD and SPOT database in femfat.ini

FEMFAT is able to start a virtual display in batch mode (by using Xvfb)

Output of survival probability

Select group by name

FEMFAT can be started several times in one working directory

SPOT: Definition of dependency of fatigue limit on ultimate strength by a polygonal line

4


New FEMFAT 5.0 GUI Layout

FEMFAT 4.8 FEMFAT 5.0

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6




7




8




9


Multiaxial Fatigue Analysis of Stochastically Loaded

Mechanical Systems

10

Critical cutting plane method

Spectral fatigue analysis

yzxzxyzzyyxxI

aaSIji

jiji

,,,,,

)(,

*2

Autocorrelation

Advantages:

- Effective numerical analysis

- Fatigue analysis based on unit loads in

frequency domain

- Multiaxial PSDs possible

New theoretical and practical

aspects:

- Material-characteristic equivalent

stresses in frequency domain

- Different technological influences, e.g.

notch support effect

- Consideration of constant stresses

- Amplitude distribution models:

- Raleigh

- Dirlik


Effect of Porosity on Fatigue Life

40% Decrease

Very large scatter

11

By courtesy of

Christian Oberwinkler,

AMB Leoben

AlSi9Cu3, die cast, R=-1, Kt=1.0, RT

Without pores

With pores

Number of cycles

Str

ess A

mp

litu

de

Tests performed at University of Leoben show, that porosity is not suitable

for fatigue life prediction because of extremely large scatter!


Crack Initation at Pores

Initial crack length dequCrack propagation dequ

12

Cracks initiate at pores with maximum size

Methods of fracture mechanics are suitable

By courtesy of Christian Oberwinkler, AMB Leoben


Kitagawa-Takahashi Diagram

No crack propagation

Crack propagation

02

tha

KS

Y a a

Pore free material

13

AlSi9Cu3, die cast, R=-1, N=1e7

Str

ess A

mp

litu

de

[M

pa

]

Equivalent diameter [mm]

No rupture

Rupture

El-Haddad

Kitagawa


Determination of Threshold of Stress Intensity Factor

Crack propagationNo crack

propagation

K Y S a

Th

res

ho

ld v

alu

e

14

AlSi9Cu3, die cast, Single Edge Bending

Stress intensity K [Mpa m]

Cra

ck p

rop

aga

tion

rate

da

/dN

[nm

/cyc]

ECS / Disclosure or duplication without consent is prohibited 15

6.)

Recalculate Material Parameters for Given Defect

Size (e.g. Pores)

Generation of

material data for

FEMFAT boundary

layer model

1.)

2.)

3.)

4.)

5.)


Predefined Defect Geometries

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BREAK for MAX

Calculate static safety factor at each time point

Output of minimum static safety factor and corresponding time step

Equivalent stress selection (BASIC & MAX): Automatic:

Max./Min. Principal Stress for gray cast iron

Von Mises for all other materials

Von Mises Max./Min. Principal Stress

17


Extension of WELD Database for Shear Data

Polygonal Line for shear notch fatigue limit:

Haigh-Diagrams for shear stress:

The shear Haigh-diagrams

are constructed in the same

way as the Haigh-diagrams

for normal stress.

Identifier: SX, SY

Identifier: SH

$ SX .... mark for shear fatigue limits of base material

$ SY .... mark for allowable shear notch fatigue strength of welding seam

$

$ ST37 ST52 QSTE690

$|--(1)--|--(2)--|--(3)--|--(4)--|--(5)--|--(6)--|--(7)--|--(8)--|--(9)--|

SX 0.0 100.0 160.0 200.0 5000.0

SY 0.0 141.0 156.0 159.0 159.0

$ 2|-(3)-|-(4)-|-(5)-|-(6)-|-(7)-|-(8)-|-(9)-|-(10)|-(11)|-(12)|-(13)|-(14)|

$ | A | B | C | W1 | D | E | F | W2 | K1 | K2 | R1 | R2 |

SH 1 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

SH 2 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

SH 3 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

SH 4 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

SH 5 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

SH 6 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

SH 7 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

SH 8 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

SH 9 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

SH10 0.867 10.00 1E30 45.0 0.867 10.00 1E30 45.0 1.0 15.0 0.26 3.85

As default setting, values

from normal notch fatigue

strength reduced by 1.41 are

used.

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Notch factors for shear stresses for each joint type for TOP and BOTTOM side (identifiers SSTO, SSBO):

$ Data for nodes in the middle of the weld seam

$

$ MNT MNB UTL1 UTL2 UTL3 UBL1 UBL2 UBL3 WTL1 WTL2 WTL3 WBL1 WBL2 WBL3 SPTO SPBO SSTO SSBO

$ ---------------------------------------------------------------------------------------

109 1.70 1.96 7.23 3.64 3.98 3.98

110 1.70 1.96 7.23 3.64 3.98 3.98

111 1.70 1.96 7.23 3.64 3.98 3.98

112 1.70 1.96 7.23 3.64 3.98 3.98

Welding seam middle nodes:

$ Data for a node at the weld seam end or begin

$

$ NCOL MAT MNT MNB UTL1 UTL2 UTL3 UBL1 UBL2 UBL3 WTL1 WTL2 WTL3 WBL1 WBL2 WBL3 SPTO SPBO SSTO SSBO

$-------------------------------------------------------------------------------------------------

CO101 109 3.06 3.00 1.96 1.66 1.90 3.76 3.98 3.98

CO102 109 3.06 3.00 1.96 1.66 2.71 2.63 3.98 3.98

CO106 109 3.06 3.00 1.96 1.66 1.90 3.76 3.98 3.98

CO107 109 3.06 3.00 1.96 1.66 2.71 2.63 3.98 3.98

Welding seam begin/end nodes:2

1If fields are empty:

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$ NCOL MAT BEPKT 1 BEPKT 2 BEPKT 3 BEPKT 4 SHEAR Top SHEAR Bottom

$ Inclination Inclination Inclination Inclination Inclination Inclination Survival Probability

$ Cycle Endur. Cycle Endur. Cycle Endur. Cycle Endur. Cycle Endur. Cycle Endur. Range of Disp. 10-90

$------------------------------------------------------------------------------------------------------------------------

CN101 109 5.00 5.00 5.00 5.00 5.00 5.00 97.7

CE101 109 1800000 1800000 1800000 1800000 2000000 2000000 1.297

CN102 109 5.00 5.00 5.00 5.00 5.00 5.00 97.7

CE102 109 1800000 1800000 1800000 1800000 2000000 2000000 1.297

CN106 109 5.00 5.00 5.00 5.00 5.00 5.00 97.7

CE106 109 1800000 1800000 1800000 1800000 2000000 2000000 1.297

CN107 109 5.00 5.00 5.00 5.00 5.00 5.00 97.7

CE107 109 1800000 1800000 1800000 1800000 2000000 2000000 1.297

$ BEPKT 1 BEPKT 2 BEPKT 3 BEPKT 4 SHEAR Top SHEAR Bottom

$ Inclination Inclination Inclination Inclination Inclination Inclination Survival Probability in Perc.

$ Cycle Endur. Cycle Endur. Cycle Endur. Cycle Endur. Cycle Endur. Cycle Endur. Range of Disp. 10-90 Percent

$ -----------------------------------------------------------------------------------------------------------------------

N109 5.00 5.00 4.00 4.00 5.00 5.00

E109 1800000 1800000 1000000 1000000 2000000 2000000

N110 5.00 5.00 4.00 4.00 5.00 5.00

E110 1800000 1800000 1000000 1000000 2000000 2000000

N111 5.00 5.00 4.00 4.00 5.00 5.00

E111 1800000 1800000 1000000 1000000 2000000 2000000

N112 5.00 5.00 4.00 4.00 5.00 5.00

E112 1800000 1800000 1000000 1000000 2000000 2000000

S-N curves for shear stresses for each joint type for TOP und BOTTOM side

Welding seam middle nodes:

Welding seam begin/end nodes:

If fields are empty, data of

normal stress S-N curves

are used, or shear stress

S-N curve of EUROCODE 3

database if available.

20


Generate 3D-Presentation for Powerpoint

21

Free Powerpoint-plugin from Ceetron

available (GLview3DPluginSetup.exe)

Displayed result, group and color bar can be

exported as VTFx-file ( Ceetron)

Start

presentation

Also node description can

be displayed

Insert a frame and

load VTFx-file


BASIC: PLAST-module extended for Mises-stress

22

Richard Edler von Mises

1883-1953

Austrian mathematician

Str

ess

Strain

Mean

Modified

Max

Modified

Min

Modified

Max

Min

Mean


BASIC: Definition of Cutting Plane Angle

23

Same cutting planes as

in MAX with 3D-option


BASIC:

New Default Setting for Equivalent Stress

24

Now the option Automatic works in the same way for BASIC and MAX:

For all materials except gray cast iron: 4.8: Mod. Equivalent Stress in Critical Plane 5.0: Scaled Normal Stress in Critical Plane

For gray cast iron: 4.8 & 5.0: Normal Stress in Critical Plane

Equivalent torsion mean stresses in planes:


Sensitivity analysis for process influences of

welding seams

Example: Influence of weld penetration degree for 45 T-joint:

FEMFAT WELD solution:

For these process parameter WELD databasefor best & worst case are provided:

penetration degree

gap

seam thickness

seam inclination angle

FEMFAT ffj-templates are provided for automatic sensitivity analysis.

Root notch factor K = 10,0 K = 6,7 K = 5,0

g

d1

d2

= d1 / d2

g

a

25


SPOT force based: Diameter and material from

connected sheets

26

Diameter = Factor*root(sheet Thickness)

Diameter is taken from property card or

CHEXA cross-section

Take material from connected shell

element

Take material from connector element

(beam, CWELD, CHEXA)

Output of material in pro-file:


VISUALIZER:


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VISUALIZER:


28

Display all T-joints

Display all overlap joints


ABAQUS interface: Import of increment 0 (e.g. from POST

OUTPUT) and shell thicknesses from forming simulation

Author: 29


Mapping of FEMFAT nodal results to elements

and export to HyperMesh

Display of element results in HyperMesh

30


Output Rainflow Matrix Data as CSV-File

31

Import and display

in Excel


Output of Survival Probability

32


Definition of Path to WELD and SPOT Database in

femfat.ini

33


Select Group by Name

Possible FEMFAT Job-file (.ffj) commands for group selection:

setValue {} {} GUI_Group:Group 10 select by label

setValue {} {} GUI_Group:Group {10 Group_Name} select by label

setValue {} {} GUI_Group:Group {Group_Name} select by name

If there are several groups with same name, the first one will be selected.

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Platform Strategy for FEMFAT 5.0

Supported hardware platforms:

Intel 686, AMD-K7 32bit Windows Server 2003, XP, Vista, 7

AMD 64, Intel 64 64bit Windows Server 2003/2008, XP, Vista, 7

AMD 64, Intel 64 64bit Linux RHEL 4-6, Linux SLES 9-11

IBM Power 4-7 64bit AIX 5.3, AIX 6.1

Other platforms (HP PA-Risc and Itanium2 under HP-UX/Linux) are not supported anymore, because:

they are not widely distributed anymore

They display rather poor performance

If these plans do not conform to your requirements, please contact us as soon as possible.

35

ECS / Disclosure or duplication without consent is prohibited 36

The FEMFAT development team wish you

much success with

FEMFAT 5.0

FEMFAT50

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