Static strength and fatigue life according to FKM-Code in HyperWorks           AutoFENA 3D:           Assessment of static...
Static strength and fatigue life according to FKM-Code in HyperWorks            Simulation explicit and                   ...
Static strength and fatigue life according to FKM-Code in HyperWorks           Overview           •      German FKM-Guidel...
Static strength and fatigue life according to FKM-Code in HyperWorks       FKM-Guideline       • Well accepted and widely-...
Static strength and fatigue life according to FKM-Code in HyperWorks       FKM-Guideline       • Assessment for           ...
Static strength and fatigue life according to FKM-Code in HyperWorks       FKM-Guideline                                  ...
Static strength and fatigue life according to FKM-Code in HyperWorks       FKM-Guideline       • Assessment procedure usin...
Static strength and fatigue life according to FKM-Code in HyperWorks       FKM-Guideline       • Necessary input values   ...
Static strength and fatigue life according to FKM-Code in HyperWorks       Software tool AutoFENA 3D       • Assessment st...
Static strength and fatigue life according to FKM-Code in HyperWorks       Integration in HyperWorks       • Necessary str...
Static strength and fatigue life according to FKM-Code in HyperWorks       Program structure                       input d...
Static strength and fatigue life according to FKM-Code in HyperWorks       Assessment procedure       •      Read in the r...
Static strength and fatigue life according to FKM-Code in HyperWorks       Load case combination       • Two load case com...
Static strength and fatigue life according to FKM-Code in HyperWorks       Calculation of stress gradient       • The stre...
Static strength and fatigue life according to FKM-Code in HyperWorks       Strength Assessment       • Static strength ass...
Static strength and fatigue life according to FKM-Code in HyperWorks       Examination       •      Visualisation of resul...
Static strength and fatigue life according to FKM-Code in HyperWorks       Documentation       • Documentation in html-For...
Static strength and fatigue life according to FKM-Code in HyperWorks       Using       • Easy to use GUI       • Storage o...
Static strength and fatigue life according to FKM-Code in HyperWorks       Material database       • Material database wit...
Static strength and fatigue life according to FKM-Code in HyperWorks       Connections       • HyperWorks                –...
Static strength and fatigue life according to FKM-Code in HyperWorks       Reliability of the results       • Assessment o...
Static strength and fatigue life according to FKM-Code in HyperWorks       Residual Stresses from CASTING       • Consider...
Static strength and fatigue life according to FKM-Code in HyperWorks       Quality       • Tested with approximately 150 t...
Static strength and fatigue life according to FKM-Code in HyperWorks       Further development       • Collaboration in th...
Static strength and fatigue life according to FKM-Code in HyperWorks       Conclusions       • The manual selection of the...
Static strength and fatigue life according to FKM-Code in HyperWorks                                                   Tha...
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AutoFENA 3D: Assessment of static strength and fatigue life according to FKM-Guideline within HyperWorks

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AutoFENA 3D: Assessment of static strength and fatigue life according to FKM-Guideline within HyperWorks

  1. 1. Static strength and fatigue life according to FKM-Code in HyperWorks AutoFENA 3D: Assessment of static strength and fatigue life according to FKM-Guideline within HyperWorks EHTC 2011, Bonn Dr.-Ing. Wolfgang Feickert Dipl.-Ing. (FH) Tim Kirchhoff Ingenieurbüro Huß & Feickert, Liederbach www.ihf–ffm.dePage 1 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  2. 2. Static strength and fatigue life according to FKM-Code in HyperWorks Simulation explicit and Software- und Experimental SoftwareTraining implicit FE-Method Product Development Services - Training Course in - Linear and nonlinear structural - Software Development - Durability Testing ANSYS and LS- mechanics - AutoFENA 3D DYNA - Acceleration - Dynamic - DYNAMID - Sales Support for Measurement - Optimisation ANSYS and LS- - Modal Analysis DYNA - Thermal Transport - Concept Development - CAD Design - Temperature- und - Reseller for Design- - Fluid Dynamic - Assessment Strain Gauge- Space - Crash Measurement - Preparation Of - Drop Test Drawings - Containment Test www.ihf–ffm.dePage 2 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  3. 3. Static strength and fatigue life according to FKM-Code in HyperWorks Overview • German FKM-Guideline • Properties of AutoFENA 3D • Software features • Quality of software • Further developments • Conclusions • Video about AutoFENA 3D www.ihf–ffm.dePage 3 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  4. 4. Static strength and fatigue life according to FKM-Code in HyperWorks FKM-Guideline • Well accepted and widely-used verification procedure in German speaking countries for analytical strength assessment for machine components • Publisher: German Engineering Federation Verband Deutscher Maschinen- und Anlagenbau ForschungsKuratorium Maschinenbau • The Guideline is continuously further developed within different research projects • It covers a static strength and fatigue life assessment for steel, cast irons (both up to 500°C) and aluminium (up to 200°C) www.ihf–ffm.de • The Guideline represents the state of the artPage 4 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  5. 5. Static strength and fatigue life according to FKM-Code in HyperWorks FKM-Guideline • Assessment for – Static strength, limit state – Fatigue limit – Fatigue strength • Calculation bases on – Nominal stresses in a section – Local stresses (effective notch stress) www.ihf–ffm.dePage 5 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  6. 6. Static strength and fatigue life according to FKM-Code in HyperWorks FKM-Guideline www.ihf–ffm.de Static stress assessment Fatigue stress assessmentPage 6 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  7. 7. Static strength and fatigue life according to FKM-Code in HyperWorks FKM-Guideline • Assessment procedure using local stresses – Fatigue action: determine effective notch stress – Fatigue resistance: against effective elastic notch stress in terms of a universal S-N curve – Summation of cumulative damage – Use adequate safety factors depending on regular / not regular inspection provided, probability of occurrence of load, non destructive testing and consequences of failure (damage), material • Results of FEM-analysis can be used • Critical points must be chosen by the user www.ihf–ffm.dePage 7 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  8. 8. Static strength and fatigue life according to FKM-Code in HyperWorks FKM-Guideline • Necessary input values – Method of calculation – Amplitude und mean value of elastic principle stresses at the reference point on the surface – Stress gradient normal to the surface or stress amplitude inside the part at a given depth – Behaviour of stress components (synchronously) – Material properties and surface treatment – Operating temperature and exposure time – Design: Thickness, average surface roughness – Safety requirements: resulting damage, probability of occurrence of load, inspection provided, non destructive testing, overload case www.ihf–ffm.dePage 8 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  9. 9. Static strength and fatigue life according to FKM-Code in HyperWorks Software tool AutoFENA 3D • Assessment strictly according to FKM- Guideline for FE-results – Program bases on the actual 5th revised edition 2003 – Some future development are optional covered • Assessment for the entire surface of a loaded structure – Assessment point = Finite Element Node • Automatic calculation of the stress gradient normal to the surface at each assessment point leads to notch sensitivity parameter www.ihf–ffm.dePage 9 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  10. 10. Static strength and fatigue life according to FKM-Code in HyperWorks Integration in HyperWorks • Necessary stress data will be provided by the HyperWorks suite • Integration as entry in the menu • Stresses, node- and element-data at all surface nodes will be read out from the HyperWorks database • Results from Radioss, NASTRAN, ANSYS and Abaqus are supported • The results of the static and fatigue calculation using the FKM-Guideline are exported as HyperMesh result file • The results of the static and fatigue assessment can be visualized in 3D within HyperView www.ihf–ffm.dePage 10 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  11. 11. Static strength and fatigue life according to FKM-Code in HyperWorks Program structure input data result data from static from FE- strength and fatigue Analysis - read data from - do calculations - reads data from assessment HyperWorks on the data data base according to - interpretation of FKM-Guideline - writes data to data HyperWorks - write data into database data base - holds the data www.ihf–ffm.dePage 11 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  12. 12. Static strength and fatigue life according to FKM-Code in HyperWorks Assessment procedure • Read in the results of the Finite Element calculation into HyperView • Export the data to AutoFENA 3D • Automatic generation of load case combinations • Assessment for the entire surface – Static strength – Fatigue limit – Fatigue strength • Examination – Post-Processing in HyperView – Report in html-Format www.ihf–ffm.dePage 12 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  13. 13. Static strength and fatigue life according to FKM-Code in HyperWorks Load case combination • Two load case combination methods – Independent load cases (e.g. pressure, wind) Definition of a arbitrary stress ratio R All linear combinations of the load cases will be calculated automatically – Dependent load cases (e.g. dead load, bolt force, pressure), which are already calculated within the FEM-Code (appropriate for non linear loads) The stresses to calculate the amplitude vary between these load cases • Simplified procedure for non-proportional stresses according to FKM-Guideline www.ihf–ffm.dePage 13 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  14. 14. Static strength and fatigue life according to FKM-Code in HyperWorks Calculation of stress gradient • The stress gradient is necessary to calculate the plasticity factor (additional support) • The stress gradient is calculated by the form functions of a 4-Node-Tetrahedron and a 8-Node-Hexahedron • The stress gradient is calculated for every node on the surface www.ihf–ffm.dePage 14 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  15. 15. Static strength and fatigue life according to FKM-Code in HyperWorks Strength Assessment • Static strength assessment • Fatigue limit • Fatigue strength – Definition of stress collective – Procedure according to Miner rule consequent – Procedure according to Miner rule elementary www.ihf–ffm.dePage 15 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  16. 16. Static strength and fatigue life according to FKM-Code in HyperWorks Examination • Visualisation of results in HyperView • Full field display of the static and fatigue utilization • All post processing features of Hyper View can be used • Further output to evaluate the reliance of the results – Non-averaged and averaged strength capacity consumed – positive stress gradient – misaligned stress tensor www.ihf–ffm.dePage 16 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  17. 17. Static strength and fatigue life according to FKM-Code in HyperWorks Documentation • Documentation in html-Format • Detailed Documentation of critical or user defined Nodes www.ihf–ffm.dePage 17 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  18. 18. Static strength and fatigue life according to FKM-Code in HyperWorks Using • Easy to use GUI • Storage of assessment parameters in a "Parameter-File", new calculations can be carried out with an unchanged parameter set www.ihf–ffm.dePage 18 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  19. 19. Static strength and fatigue life according to FKM-Code in HyperWorks Material database • Material database with all non-aluminium materials according to the FKM-Guideline (approximate 200 materials) • User can define his own materials • Filtering of materials according to material groups • Material definition will be mapped to parts according to their element component name www.ihf–ffm.dePage 19 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  20. 20. Static strength and fatigue life according to FKM-Code in HyperWorks Connections • HyperWorks – Actual version 11.0 – Integration in HyperView – Support of solid elements • Connection to ProCAST cast simulation – Import Data from ProCAST www.ihf–ffm.dePage 20 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  21. 21. Static strength and fatigue life according to FKM-Code in HyperWorks Reliability of the results • Assessment of results at each Finite Element Node – Comparison of averaged and non-averaged results (analogue element stresses and nodal stresses) • Misalignment of the stress tensor from the surface normal – Indicator for an insufficient discretisation in the interior direction • Graphical output of error codes – e.g. positive stress gradient in the interior direction www.ihf–ffm.dePage 21 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  22. 22. Static strength and fatigue life according to FKM-Code in HyperWorks Residual Stresses from CASTING • Consideration of residual stresses due to different cooling rates during the casting process (ProCAST) • Residual compressive stress at the surface increase the fatigue strength, residual tension stress decrease the fatigue strength • Under cyclic loading the mean stress is changed by residual stress. Mean stress sensitivity of alloys and grey cast are significantly high • Result mapping from casting simulation on FE-Model, including transformation of different coordinate systems and use of symmetry www.ihf–ffm.de 79 % 91 % Utilization with out Utilization with residual stresses residual stressesPage 22 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  23. 23. Static strength and fatigue life according to FKM-Code in HyperWorks Quality • Tested with approximately 150 test cases – Automatic testing for each new release • Benchmarks against other software of competitors • Used by customers like: Liebherr, Knorr Bremse, Siemens and Voith Paper • Collaboration in Forschungskuratorium Maschinenbau: Fachkreis Bauteilfestigkeit; the research agency of the German Engineering Federation • Collaboration in project accompanying work shops for the next edition of the FKM-Guideline www.ihf–ffm.dePage 23 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  24. 24. Static strength and fatigue life according to FKM-Code in HyperWorks Further development • Collaboration in the development process for the next edition guarantees a continuous progress of the software • Future development of the FKM-guideline can be offered as optional features before the finishing of the revision process • Customer request will be implemented in new software releases • Continuous customisation of all connections • Next steps: - consideration of shell elements - consideration of welded seams www.ihf–ffm.dePage 24 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  25. 25. Static strength and fatigue life according to FKM-Code in HyperWorks Conclusions • The manual selection of the critical point is not necessary • No manual data input of stress values into the code procedure • Thanks to the graphical visualization of the utilization interpreting the results is much easier • Secondary critical areas can be detected and material in non critical regions can be saved • The quality of the FE-Model in respect to the assessment can be checked • The calculation is more reliable • Using HyperWorks to provide the input data and visualize the results opens a broad range of applications www.ihf–ffm.dePage 25 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert
  26. 26. Static strength and fatigue life according to FKM-Code in HyperWorks Thank you for your attention If you want to hear more about the product contact me at our booth and participate in our raffle www.ihf–ffm.dePage 26 of 26 / November 9th 2011 / Name: Fe, TK / Conference: HTC 2011, Bonn ingenieurbüro huß & feickert

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