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CAE Simulation & Solutions Maschinenbau Ingenieurdienstleistungen GmbH Dr. Wolfgang Krach, Dr. Walter Vonach, Dr. Nikolaus Friedl LIMIT 2017 Page 1 www.cae-sim-sol.com

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Page 1: CAE Simulation & Solutions Maschinenbau ... · CAE Simulation & Solutions Maschinenbau Ingenieurdienstleistungen GmbH ... Abaqus/CAE, ANSYS, NX ... Abaqus Catia FE

CAE Simulation & Solutions Maschinenbau Ingenieurdienstleistungen GmbHDr. Wolfgang Krach, Dr. Walter Vonach, Dr. Nikolaus Friedl

LIMIT 2017 Page 1www.cae-sim-sol.com

Page 2: CAE Simulation & Solutions Maschinenbau ... · CAE Simulation & Solutions Maschinenbau Ingenieurdienstleistungen GmbH ... Abaqus/CAE, ANSYS, NX ... Abaqus Catia FE

Page 2LIMIT 2017www.cae-sim-sol.com

Who we are:

Engineering service provider▪ Based in Vienna, Austria▪ Company founded 2002

Main fields of activities▪ Structural mechanics Strength assessments of structures Simulation of production processes More than 700 projects conducted

▪ Computational fluid dynamics Since 2010 Flow and heat transfer projects

▪ Software development Primarily for internal use LIMIT since 2004, available for

customers since 2010

Company Profile and History

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Page 3LIMIT 2017www.cae-sim-sol.com

Training/Support AllFEA Topics All

Services, Methodology & Software

Patran/NastraMarc

Stand Alone Applications

Fluent /OpenFoam

LIMIT

Software Sales

Finite Element AnalysisStrength assessments

Flow Simulation /Energy Transfer

SWX / FlowSimulation

SWX / Simulation

CAD - Integrated

HyperworksAbaqus

CatiaDraft SWX

Measurments/Tests

Servicesfrom idea to design

Page 4: CAE Simulation & Solutions Maschinenbau ... · CAE Simulation & Solutions Maschinenbau Ingenieurdienstleistungen GmbH ... Abaqus/CAE, ANSYS, NX ... Abaqus Catia FE

Efficient and conforming-to-standard fatigue assessment with LIMIT

LIMIT 2017 Page 4www.cae-sim-sol.com

The Software

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LIMIT 2017 Page 5www.cae-sim-sol.com

Main Objective

Finding critical loads and load cycle numbers

Checking all critical positions

Applying different design codes

▪ Strong focus on welds and

▪ Large structures

Motivation for LIMIT

?

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LIMIT 2017 Page 6www.cae-sim-sol.com

LIMIT Within the Simulation Process

FE modelPatran, Hypermesh,

Abaqus/CAE, ANSYS, NX

Design: 3D-CAD

Finite Element Input.bdf, .out, .dat, .inp

FE Results.fil, .odb, .op2, .rst

LIMIT-SOLVERAnalysis

LIMIT-VIEWERPost processing

FE SolverNastran, Abaqus, ANSYS

Midsurfaces and shell elements

3D-CAD

Degree of utilization in welds

LIMIT-CAEDefinition of assessments

in the GUI

Global iteration loop, changing

geometry

Local loop, e.g. changing weld quality

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LIMIT 2017 Page 7www.cae-sim-sol.com

Effects taken into account▪ stress gradients normal to surface

▪ surface factors

▪ temperature

Assessment

Assessment of base material▪ static strength / fatigue strength

▪ Very efficiently using FKM guideline, 6th edition

Crank shaft

Centre pin

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LIMIT 2017 Page 8www.cae-sim-sol.com

Assessment

Assessment of welds with nominal or structural hot spot stresses

a.) complex structures b.) simple definition of welds c.) visual check of weld geometry

a.)

b.)

c.)

underframe metro

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LIMIT 2017 Page 9www.cae-sim-sol.com

Assessment

Assessment of welds with nominal or structural hot spot stresses

▪ static and fatigue assessment ▪ numerous codes available ▪ simple post processing

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LIMIT 2017 Page 10www.cae-sim-sol.com

Features/Facts

The Software

Assessments:

▪ Static strength

▪ Fatigue strength

▪ Finite life strength

Codes/Guidelines:

▪ FKM-Guideline

▪ Eurocode 3 and 9

▪ DVS 1612 / 1608

▪ (EN 17149 planned)

▪ User defined

▪Crane code : DIN15018, EN13001

Stress types:

▪ Nominal stress

▪ Structural hot spot stress

▪ Local stress

▪ Embedded sensors

Interfaces:

▪ MSC Nastran / NX Nastran

▪ MSC Marc

▪Radioss / Optistruct

▪ Ansys

▪ Abaqus

▪ Catia FE (Tetras)

▪ SolidWorks

Mesh Tet10

Structural hot spot assessment

Flange

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LIMIT 2017 Page 11www.cae-sim-sol.com

Advantages using LIMIT

Reduction of time-to-market

Reduction of risk of failure▪ Comprehensive and accurate assessment

▪ Quality is improved, especially compared to manual assessment

▪ Saves money due to less cases of warranty

Simple to use for engineers => low costs for training

Advantages using LIMIT

fatigue cracks in welds

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References

▪ AMST-Systemtechnik GmbH

▪ AUDI, Werkzeugkonstruktion, Germany

▪ Bühler AG, Switzerland

▪ China Energine International Ltd.

▪ FEMCOS-Ingenieurbüro mbH, Germany

▪ Gardner Denver Schopfheim GmbH, Germany

▪ Hydromek, Turkey

▪ IBV-Engineering, Germany

▪ IFF Engineering & Consulting GmbH, Germany

▪ Istanbul Technical University, Turkey

▪ K + V Ingenieurgesellschaft mbH, Germany

▪ Ludwig Engel KG, Austria

▪ Liebherr-Transportation Systems GmbH & Co KG

References

▪ LogoMotive GmbH, Germany

▪ MAV-START, Hungary

▪ NEWAG, Poland

▪ PESA Bydgoszcz SA, Poland

▪ Prisma Engineering, Austria

▪ RUAG Schweiz AG, Switzerland

▪ Stadler Valencia, Spain

▪ STREICHER Maschinenbau GmbH & Co. KG, Germany

▪ TUV Rheinland Rail Sciences, Inc., Nebraska, USA

▪ Vossloh Locomotives, Kiel

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Stress Concepts for Welded Structures

FKM, Fatigue/Static Strength

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Modelling Techniques in LIMIT

Weld Analysis with LIMITSingle sided fillet weld▪ Fillet throat critical => stresses in throat

needed!A.) Using section forces from shell model

B.) Using section forces from solid model & LIMIT sensors

C.) R1-effective notch

Sensors

A.)

B.)

C.)

Cracks

Load

no singularities

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page 15www.cae-sim-sol.com LIMIT 2017

Modelling Techniques in LIMIT

Weld Analysis with LIMITDouble sided fillet weld▪ Weld toes critical => simpler approach

A.) Shell stresses can be used

B.) Solid model & LIMIT sensors

C.) CAB-method (structural stressat transition lines)

Sensors

A.)

B.)

C.)

Cracks

Load

r = √(2 x a), avoids singularities

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page 16www.cae-sim-sol.com LIMIT 2017

Modelling Techniques in LIMIT

Weld Analysis with LIMITExample: Solid modeling & weld assessment with sensors

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page 17www.cae-sim-sol.com LIMIT 2017

Strongly mesh dependant results:

Stresses in Welded Structures

!

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page 18www.cae-sim-sol.com LIMIT 2017

Stress concepts for welded structures

Nominal stress ▪ classic concept

Notch stress(peak stress)

Structural hot spotstress (IIW)

Stresses in Welded Structures

F

F

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page 19www.cae-sim-sol.com LIMIT 2017

Nominal stresses

Stresses relating to nominal section

Permissible stresses include: ▪ Stress increase due to change in

stiffness (I)

▪ Local notch effect throughweld root or weld toe (II)

Stress Concepts

(II)

(I)

Source: EC3

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page 20www.cae-sim-sol.com LIMIT 2017

Structural hot spot stress

According to IIW(International Institute of Welding)

Stresses include structural effect (I)

Permissible values include notch of weld (II)

Stress Concepts

xx

Structural Hot Spot Stress

(II)

(I)

Source:FKM Guideline 2012

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Stress concepts

Peak Stress

Welded Assembly

Effective notch stress

According to Radaj

Toe and root modeled with Radius 1mm

Linear elastic analysis

Calculate stress range

For structural steel: FAT 225 (at 2 mio. cycles)

Only for detail studies usable

Notch stress

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page 22www.cae-sim-sol.com LIMIT 2017

Structural Hot Spot / Nominal Stresses for Solid Elements

Sensors embedded within the solid model

Extracting structural stresses for weld toes

Linear extrapolation scheme according to IIW

Averaged stress data comparable to shell results

Assessment Concepts, Sensors

Hot Spot Stress

Sensor

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page 23www.cae-sim-sol.com LIMIT 2017

Structural Hot Spot Stresses for Solid Elements

Generation of sensors with LIMIT SensorManager

Assessment Concepts, Sensors

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page 24www.cae-sim-sol.com LIMIT 2017

Structural Hot Spot Stresses for Solid Elements

Sensors: definition of welds in same way as for shells

Assessment Concepts, Sensors

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Critical Points

n

m

Weld Analysis with LIMITBasic features of LIMIT▪ Checking all critical points

(red circles) Base material

Weld section

Toes and Roots

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Assessment Points within LIMITAre used to perform the fatigue analysisfor potential areas of crack initiation

Are defined relative to shell normal

P1 to P4 …. Weld Section

▪ P1, P4 … toe

▪ P2, P3 … root

P5 and P6 …. Base Material

Weld dimensions

▪ A-Bot … welded from bottom side

▪ A-Top … welded from top side

Root Position (midplane to root)

▪ D-Bot … welded from bottom side

▪ D-Top … welded from top side

Stresses and Section Forces

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page 27www.cae-sim-sol.com LIMIT 2017

Single sided fillet weld, Stresses in P3, roott … sheet thickness

continously welded

Stresses and Section Forces

Stress lateral to weld direction at rootOnly n , m = 0A … weld sectione … excentricity

s, P3 = n / A + n 6 e / A² = n (1 / A + 6 e / A²)

snom = n / As, P3 = snom (1 + 6 e / A)

Example: A = t, e = t (full excentricity)s, P3 = snom (1 + 6)

BottomTop

A

P4 P3

t/2t/2

n

m

e

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t1

t2a

Only nominal stress, root:FATll = 100FAT= 36 + Excentricity!FATt = 80

FAT classes, one sided fillet weld:

Typical values:

FAT-Classes

s

sll

t

t2

sll

s

s

t1

Only nominal stress, toe:FATll = 100FAT= 71FATt = 80

Nominal stress, toe:FATll = 100FAT= 71 80FATt = 80

Structural stress, toe (IIW)FATll = 100FAT= 100FATt = 80

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Typical results

In the following section results are compared and documented for different weld types :

a.) One sided full penetration weld

b.) Double sided fillet weld

c.) One sided fillet weld

Results

a.) b.) c.)

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Comparison for different geometries

Degree of Utilization (DoU)

Results

DoU = 4,88DoU = 0,71DoU = 0,85

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Apply for a free test license and experience the benefits for your projects!Please contact:Dr. Nikolaus [email protected] +43 1 974 89 91-12