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Fatigue Analysis in Ansys Workbench

This document discusses fatigue analysis methods in Ansys Workbench. It describes two categories of fatigue analysis: crack formation and crack growth. For crack formation analysis, stresses are used to predict failure cycles from S-N curves, while crack growth analysis models crack propagation. The document outlines fatigue analysis procedures, mean stress corrections, multiaxial fatigue approaches, and types of cyclic loading simulations supported in Ansys Workbench.

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Ashokkumar Vellore
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604 views14 pages

Fatigue Analysis in Ansys Workbench

This document discusses fatigue analysis methods in Ansys Workbench. It describes two categories of fatigue analysis: crack formation and crack growth. For crack formation analysis, stresses are used to predict failure cycles from S-N curves, while crack growth analysis models crack propagation. The document outlines fatigue analysis procedures, mean stress corrections, multiaxial fatigue approaches, and types of cyclic loading simulations supported in Ansys Workbench.

Uploaded by

Ashokkumar Vellore
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Fatigue analysis in Ansys workbench

2
Introduction:

In materials science, fatigue is the weakening of a material caused by cyclic loading that results in progressive and localized structural damage and
the growth of cracks. Once a crack has initiated, each loading cycle will grow the crack a small amount, typically producing striations on some parts of
the fracture surface. The crack will continue to grow until it reaches a critical size, which occurs when the stress intensity factor of the crack exceeds
the fracture toughness of the material, producing rapid propagation and typically complete fracture of the structure.
There are two general categories of fatigue analysis:

• Fatigue based on crack formation.


• Fatigue based on crack growth.
The choice of analysis type is based on the given application.
• When in the design phase, or for components requiring only a few cycles of life, crack formation may be sufficient.
• For highly engineered parts, for components that are manufactured in bulk such as automotive parts, or for in-service life prediction, crack growth
may be required.

Crack Formation Crack Growth

3
Methods of Fatigue/Fracture Analysis

Cracks/flaws are not explicitly considered.


Use ANSYS to predict far-field (un-cracked body) conditions.
ANSYS results are fed to a fatigue analysis tool.
• Basic approach could be a S-N table look-up, performed by hand or via macros.
• More comprehensive fatigue analysis using nCode.

Crack is not included in ANSYS analysis, but stress field in crack region is fed to separate fatigue crack propagation tool, such as nCode.
Crack is included in ANSYS model.
• Need to continually update mesh to account for crack growth.
• May or may not know crack path.
• Various methods used to obtain K, which is then used with a crack growth law to determine remaining life. Additional energy approaches
include virtual crack closure technique (VCCT) and cohesive zone modeling, typically used in delamination prediction.
Methods of Fatigue/Fracture Analysis

Typical procedures for performing fatigue crack formation analysis:


Simple cyclic loading, R=-1
• Model minimum and maximum loadings.
• Obtain stress range () at critical location.
• Find cycles to failure using S-N data.
Simple cyclic loading, R-1
• Model minimum and maximum loadings.
• Obtain mean stress and stress range at all points.
• Find cycles to failure by:
— Obtaining test data for varying R.
— Plot mean stress vs. alternating stress in
Goodman Diagram.
Complex loading:
• Perform a comprehensive fatigue analysis using nCode.
Goodman Diagram

To include the effect of mean stress, approaches have been developed to take the mean stress into account.
— The alternating stress is plotted against the mean stress.
— The straight line representation is called the Goodman diagram.
• The Goodman diagram is typically preferred in engineering design.
• Actual data can vary around lines by being either concave or convex.
— Points below Goodman line are considered safe, points above line are considered failed
Fatigue Curves
Stress-life curve:

Makes no attempt at modeling plasticity.


Appropriate for high cycle fatigue.
Strain-life curve:
— Models material yielding and plasticity.
— Appropriate for low cycle fatigue.
Fatigue Loading
Material fatigue curves are created with constant amplitude sinusoidal loading.
• Typically with a zero mean stress, i.e. fully-reversed loading.
• Real loading can be constant amplitude, blocks of different amplitudes, or variable amplitude, and can have non-zero mean stress.
Rainflow Cycle Counting

To account for variable amplitude loading in fatigue calculations, must have a method to define fatigue cycles in a varying waveform.
• Rainflow cycle counting is a method of finding fatigue cycles in a varying waveform.

Peak valley extraction Reorder to start from

Absolute Mean No.


Max

450 225 1

50 150 1

100 300 2

Continue by draining next lowest, etc.


Drain water starting at lowest valley, measure total & mean depth drained
Miner’s Rule of Damage Accumulation
To include the effect of multiple blocks of different amplitude cyclic loading, Miner’s rule of damage accumulation is used.
• Calculates partial damage for each amplitude loading.
• Failure is predicted when the sum of all partial damage equals one.

— Miner’s rule is very simplistic (for example, the order of loading has no effect), but it is widely used.
Elastic-Plastic Corrections

For low-cycle fatigue analyses, where plasticity plays a role, two approaches are available:
• Calculate the nonlinear material response and use in fatigue calculations.
• Use linear material response with a correction to account for material yielding, typically used for localized regions of yielding in notches.

The Neuber approach is an example of a plasticity correction.


• Assumes elastic strain energy = plastic strain energy.
• Can therefore calculate plastic response directly from elastic solution.
Mean Stress Corrections

Fatigue damage is influenced by the mean stress of each cycle.


Mean stress correction methods allow the effect of mean stress to be modeled
and taken into account.
Supported methods:

• Goodman

• Gerber
• Interpolate
• FKM
• Goodman Tension Only
• Gerber Tension Only
Additional Fatigue Analysis Features
Time-history compression
 Time series analysis can be accelerated with various methods.
 Peak-valley method uses only the load reversals.
 Limits method uses only the max and min of each load channel.

Addressing multiaxial fatigue.


Condense stress tensor down to a single stress, such as a signed Von Mises or absolute maximum principal value.
Critical plane approach finds plane with the most damage
Types of Fatigue Loading
Supported cyclic loading in nCode:

Constant amplitude.
• Apply loading in FE analysis.
• Loading is scaled assuming sine wave.
Time series.

 Apply loading in FE analysis.


 Define load time history factors to scale FE loading.
Time step – transient dynamic.

 Apply transient loading in FE analysis.


 Loading is defined from each time step read in.
Duty cycle.

 Combination of various loadings.


Vibration – frequency domain.

 Run harmonic FE solution.


 Define PSD loading in nCode.

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