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2014

SIMULIA Technology Update

fe-safe and 3DEXPERIENCE Durability Apps

David Hawla, Pawel Sobczak, Giovanni De MoraisOctober 19, 2016

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16

Disclosure

The information on products, technology or customers contained in this presentation is proprietary to Dassault Systèmes and is offered in confidence.

Dassault Systèmes makes no warranty or commitment regarding this information. Dassault Systèmes, in its sole discretion and with no notice, may revise, eliminate or otherwise alter any functionality or product plan to which the information disclosed is related.

This information is presented solely for discussion purposes.

This information should not be used as the basis for any current purchase decision from Dassault Systèmes.

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14 What will be covered

fe-safe Technology and Product Update

� 3DX R2015/16x/17x Durability Apps

� Weld fatigue

� FKM guidelines

� TCD

� Vibration fatigue

� ANSYS Workbench component

� Power-of-the-portfolio enhancements

� General enhancements

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14

3DEXPERIENCE Durability Validation App

� The first integration of

durability analysis with CATIA,

data management, and the

SIMULIA Structural Validation

app

� Focused on Designer

Engineers

� Available from 2015x

� Changes in Structural

Validation app in R2017x

apply

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14 Key Features

3DEXPERIENCE Durability Validation App

� Integrated with the Structural Validation app

� Automated meshing

� Runs Abaqus and fe-safe solvers with one click

� All data managed

� Material data assigned in one place for FEA and

fatigue analysis

� Load history restricted to cycling all loads

simultaneously with constant amplitude

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3DEXPERIENCE Durability Apps

Structural Validation R2017x changes relevant for Durability Validation

�Solution Mode and Contact

� Linear vs. Nonlinear choice

� Bonded or small sliding contact available for linear solutions

�Mesh Controls

� Global mesh density for the model

� Finer mesh density control in local regions, e.g. around notches

Durability/fatigue expert app/s

�First of many releases in one of the FD releases of R2017x next year

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� Supports spot welds modeled with:

� Abaqus, Nastran, and ANSYS Beam elements

� Abaqus Fasteners

� Nastran ACM2 elements

� Welds may join 2, 3, or 4 sheets—automatically detected

� Sheet thicknesses are automatically detected

� Nugget size may be specified or defaulted

Beam connection

Weld Elements for SS Calculation

Hong, J. K., “The Development of a Simplified Spot Weld Model for Battelle Structural Stress

Calculation,” Battelle, SAE World Congress, 2011 (2011-01-0479)

Weld fatigueVerity in fe-safe 6.5-03 Enhancements

Extended Support for Spot Weld Analysis

Now supports Nastran ACM2 elements

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14 Verity—Improved Weld Info Detection for Solid Models

Weld fatigue

� In 6.5-01 automatic detection of weld info for solid element models:

� Crack planes

� Weld toe node list

� Through-section node set per toe node

� Element set through section

� In fe-safe 2016 through-section nodes per toe node for curved weld lines is more robust

� Meshes are never as perfect as Verity theory expects

� Corrected handling of collapsed hex elements used instead of true penta/pyramid elements

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14 Verity Enhancement—Weld Info Detection for Shell Models

Weld fatigue

� fe-safe 2016 release extends the

automatic detection to shell element

models

� fe-safe 2017: top/bottom convention

made consistent with solids

� What about multiaxial weld fatigue,

i.e., combined shear and normal

stresses? Still a very high priority, but

too early to say which release

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14 Verity Enhancement – Nastran CWELD Element Support

Weld fatigue

� Nastran CWELD is a fastener element connection for modeling spot welds

� Various forms of the CWELD element exist, namely, point-to-point, point-to-patch, and

patch-to-patch

� fe-safe 2017 supports all point-to-point and point-to-patch variations

� Forces at the beam connector ends are used to generate structural stresses in the

Verity Spot Weld algorithm

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14 Other Changes

Weld fatigue

� Top-level menu item changed from Verity to Weld Preparation

�Attribution of IP that belongs to Battelle made clearer and more specific in user

interfaces

�Done in preparation for future multi-axial options and to protect our own IP

� New agreement with Battelle

�Allows for including Verity in extended packaging, but this will not be available until

one of the fe-safe 2017 FD releases next year

�Also allows for including in future 3DEXPERIENCE durability apps—not next year

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14

FKM GuidelinesFKM Guidelines “Analytical Strength Assessment of Components”

� Implementation based on 6th Edition

� Assessment of the fatigue strength using local stresses (Chapter 4)

� For non-welded components only

� Implemented in fe-safe 2016 FP1605 and includes

� Variable amplitude fatigue

� Mean stress effects

� Non-proportional loading supported via loading blocks

� Relative stress gradient calculation for 3D elements

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Job Setup: Material Properties

FKM Guidelines

� Additional material properties for FKM

� Material Type

� Elongation (%) [only required for wrought Al]

� Grey Iron Index [only required for GJL]

� Taylor ‘L’ parameter reused to define a maximum search depth for stress gradient calculation

� Two new material databases in installation folder (not loaded by default):

FKM_Fe.dbase and FKM_Al.dbase

� User can add their own materials too (of course)

…

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Job Setup: Group Properties

� fe-safe can have groups of elements or

nodes with different properties

� FKM requires surface finish as a value

�Rz (µm)

�Using the new .kt2 definition file

FKM Guidelines

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Job Setup: Group Properties � Can choose same algorithm for multiple groups but provide different parameters for each group; e.g., size factors, notch/unnotched, etc. can vary by group

FKM Guidelines

Consequence of failure

Casting factor

Technological size factor: Kd,mSurface treatment type

Section factor: np

Algorithm’s mean stress correction Version of Minor’s rule

Coating factor: KS < 1 for coated aluminum

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14 Job Setup: Loading

� Proportional loading

�Datasets should be in the same block using scale &

combine and have synchronized load histories

� Non-proportional loading

�Non-proportional loads should be in a separate blocks

�Utilization will be summed over the blocks

� Temperature handling

� Isothermal per block or use a temperature dataset for

nodal temperature

FKM Guidelines

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14 Output

� Largest utilization due to combined stress is reported on completion

� (≤1 is safe)

� Along with the element/node number

� Don’t confuse with FRF (≥1 is safe)

� Utilizations due to individual types of stress are also reported for each direction

� Contour fields written to results files

FKM Guidelines

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Theory of Critical Distances (TCD)Background

Whether the crack will propagate or not is defined by the stress some distance below the surface.

The ‘critical distance’ L is a material property obtained from ∆Kth

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Theory of Critical Distances (TCD) Recap

� fe-safe calculates the fatigue life to crack initiation

and the FRF/FOS

� fe-safe uses the subsurface stress to recalculate the

TCD FRF/FOS

� The latter may allow higher stresses if the initial

cracks are accepted

Surface FRF TCD FRF

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Theory of Critical Distances (TCD) Simple Interface

� Material data: ∆Kth or Taylor’s L

� Make sure FRF and/or FOS is turned on

� Turn on TCD

� Element size ~L/2 near surface

� Avoid Goodman mean stress corrections, especially for high mean stress

� Most recent enhancements:

� Improved handling of second-order and penta/pyramid elements (6.5-03)

� Corrected handling of collapsed hex elements used instead of true penta/pyramid elements (fe-safe 2016)

� Ongoing investigating additional algorithms for use with the point or line methods

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Vibration fatigueRe-cap

� Time-domain

�Available for more than five years

� fe-safe reads modal stresses and modal dynamic responses and uses standard scale &

combine to create stress histories for each element/node

� Frequency-domain

� Introduced in fe-safe 6.4-02, limited to Dirlik method with von Mises stresses

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Vibration fatigueTime-Domain Fatigue Analysis

� For Abaqus workflows fe-safe 2016 will generate the load definition automatically

� For ANSYS workflows fe-safe 2017 reads an MCF file as a signals file. The user

must then combine the mode’s generalized displacement signal with its stress

dataset

� For Nastran workflows, fe-safe reads a PCH file as a signals file. The user must

then combine the mode’s generalized displacements signal with its stress dataset

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Vibration fatigueFrequency-Domain Fatigue Analysis—fe-safe interface

� Select the PSD algorithm for the group/s the usual way

� Set algorithm settings via FEA Fatigue�Analysis Options

Auto-generated PSD loading block

Showing fe-safe

2017 interface

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Vibration fatigueFrequency-Domain Fatigue Analysis

fe-safe 6.5:

� Critical Plane Approach

� Normal-only

( ) T

shearG f d G dσ= ⋅ ⋅

( )

( )

( )

( )( )( )

2 2

1 3

2 2

1 3

2 2

1 3

1 1 3 3

1 1 3 3

1 1 3 3

2

2

2

x x

y y

S z z

x y x y

y z y z

x z x z

e e

e e

e e

e e e e

e e e e

e e e e

d

− − = −

− − −

( )

( )

( )

( )( )( )( )( )( )

1 3

1 3

2

1 3

2

1 3 1 3

1 3 1 3

1 3 1 3

2

2

2

2

x x

y y

z z

x x y y

y y z z

x x z z

n

e e

e e

e e

e e e e

e e e e

e e e e

d

+

+

+

= + + + +

+ +

ShearNormal Normal+Shear

fe-safe 2017:

� Combined normal and shear

fe-safe 2016:

� Normal-only or shear-only

( )

( )

( )

( )( )

( )( )

( )( )

22 2

1 3 1 3

22 2

1 3 1 3

22 2

1 3 1 3

1 1 3 3 1 3 1 3

1 1 3 3 1 3 1 3

1 1 3 3 1 3 1 3

1

1

1

2

1

2

1

2

1

x x x x

y y y y

z z z z

x y x y x x y y

x z x z x x z z

y z y z y y z z

ns

e e k e e

k

e e k e e

k

e e k e e

k

e e e e k e e e e

k

e e e e k e e e e

k

e e e e k e e e e

k

d

− + +

+ − + + +

− + + += − + + +

+ − + + + +

− + + + +

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Vibration fatigueFrequency-Domain Fatigue Analysis

fe-safe 2016:

� Tovo and Benasciutti Method

� Addresses mean and residual stresses

� Weights damage evaluated by narrow and broad band distributions

TB Method Dirlik Methodfailure

non-failure

( )1RFC NB BB

DbD D b= + −

Level Crossing

Distribution

Range Count

Distribution

1e6 repeats 6e6 repeats

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Vibration fatigueFrequency-Domain Fatigue Analysis

fe-safe 2016:

� Automatic population of the Input PSD Matrix

from multi-channel time history data

00 0

0 x

N

N NN N N

PSD PSD

G

PSD PSD

=

O

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Vibration fatigueFrequency-Domain Fatigue Analysis

fe-safe 2017 enhancements:

� Auto-generation of PSD loading definition

� ODB workflow: Modes and GU on same file

� Nastran: Read generalized displacements (per mode as function of frequency) from .pchfiles (one .pch per subcase)

� The long tail problem has been addressed,

eliminating the over-conservativism in Dirlik’s

PDF integration where most of the damage is

caused by unrealistic stresses

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� Basic fe-safe workflows and basic loading setup will be possible without entering the fe-safe GUI

� Interoperation with fe-safe GUI to configure more complex workflows

� Implemented with ANSYS v16

� Long-term technology agreement to ensure we can develop, test, and support the Workbench

component (covers TOSCA too)

ANSYS Workbench Integrationfe-safe 2016

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ANSYS Workbench Integration

The material can be controlled

from Mechanical

The scope of the analysis can be

configured (named selections or

bodies can be used

Basic dataset-sequence loadings

can be defined

fe-safe 2016

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Power-of-the-Portfolio Enhancements

� Diagram shows a common simple

workflow for a DOE task driving

Abaqus and fe-safe in sequence

where the most important input to

fe-safe is the ODB output from

each run of Abaqus

Isight fe-safe Component

� The component interface allows you to select many fe-safe settings as Isight drivable parameters

� Has been available several years

� fe-safe 2016: Improved clarity of Material and Group settings in Isight

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Power-of-the-Portfolio EnhancementsSimpack Flex-body Coupling with Abaqus and fe-safe

.inp AbaqusSubstructure

matricesSimpack fe-safe

GU per mode

Modal stresses

Fatigue life contour data

� Streamlined process for coupling Abaqus,

Simpack, and fe-safe

� Simpack 9.10

� fe-safe 2016 FP1621

� Abaqus 2016Contact Stefan.DIETZ@3ds.com for more detail

Load definition

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14 Improved Batch/Macro Usability

Power-of-the-Portfolio Enhancements

� Enhanced management of projects in fe-safe 2016

� Projects can be exported to and imported from a single

compressed file

� User can select specific categories of files for export

� Helper macro can be written out for later batch submission

� Batch processing training course developed

� Bug fixes and several small enhancements done to

significantly improve robustness and reliability

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Power-of-the-Portfolio Enhancements

fe-safe 2016

� Both SIMULIA FlexNet and DSLS now fully support redundant servers when specifying license servers

� All add-on products are supported via DSLS—but they are not covered by Extended Packaging

� Client QFX/QAX licence no longer required when fe-safe run via the command line

fe-safe 2017

� GUI auto-timeout after 60 minutes. Valuable for users sharing extended packaging license pools

� Automatic looping of license checker. Valuable for batch processes that might need to wait for a license to become available

� Precheck for macro analyses: Tools�Check Macro Syntax

� Read DSLS config file to control licensing location

Improved Batch/Macro Usability

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14 Extensions to FEA Support

General Enhancements

� Support for the latest Abaqus ODB

� Support for ANSYS RST files:

� fe-safe 2016 GA and FP1605: full support for ANSYS 15.0, 16.0, 16.1, 16.2

� fe-safe 2016 FP1613 and FP1621, and fe-safe 2017: full support for ANSYS 15.0, 16.0, 16.1, 16.2, 17.0

� Plugins can request nonstandard variables in ANSYS RST reader (fe-safe 2016)

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General EnhancementsMaterial Database

� In fe-safe 2016 material database can

be opened directly from the fe-safe GUI

� Still a way to go before truly integrated

� Updated with new materials

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General EnhancementsNew Fatigue Analysis Algorithms in fe-safe 2016

� Manson-McKnight Octahedral fatigue algorithm

� An algorithm from the NASALife specification uses a Manson-McKnight multiaxial (stress-based,

finite-life method) fatigue algorithm for the assessment of aero-engine components

� The algorithm investigates all possible pairs of load data points to determine critical plane

orientation

� The Findley combined shear and normal stress method is released as an fe-safe plug-in

for infinite life fatigue assessment

� The method uses S-N curves and critical plane searching

� Paper presented at NAFEMS World Congress 2015 provides more detail—contact

Giovanni.DEMORAIS@3ds.com

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General Enhancements

� More robust handling of collapsed elements

� Add support for many more loading blocks

(>4097)

� Added the Abaqus Licence Server binaries to

the fe-safe distribution

� Extend the material's default algorithm selection

to include plug-in algorithms

� Enable use of EN table data in TURBOlife

� Academic and teaching licences are now

supported

Other fe-safe 2016 Enhancements

� Drag-and-drop can now be used to append FEA

solutions

� The General FEA Options dialog has been re-

organized for clarity

� The Algorithm picker dialog has been

redesigned

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General Enhancements

� Temperature and temperature-dependent material properties contour fields

� Interpolated UTS and Fatigue Strength at lower and upper life limits (e.g. 1E4 and 1E7)

� More consistent coverage of both pre- and post-Neuber corrected stress, adding:

� Pre-Neuber corrected stress and amplitude contour field for worst cycle

� Post-Neuber stress history on critical plane for start and end points of cycles

Other fe-safe 2017 Enhancements

� Read ASAM MD4 binary file as signal data file

� Support for non-integer repeats in loading definition (from 1.0 to 1e9)

� Read NASTRAN OP2 with nodal coordinates in double precision

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listen to our durability analysis users,

we can help them optimize the fatigue

performance of their products