© 2008 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

2008 International ANSYS Conference

Reliability and Durability Analysis usingANSYS Workbench and nCode DesignLife

Jeff MentleynCode International

© 2008 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

Agenda

• Company Overview• nCode DesignLife• Integration within ANSYS Workbench• Frequency Based Fatigue Example• Summary

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…... through a unique combination of measurement instruments, software and services

nCode International

25 years of helping customers:eliminate unexpected structural failures and

improve product lifecycle performance

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DesignLifeTM

Streamlining the Virtual Fatigue Engineering Process

• Powerful Fatigue Analysis Technology

• Integrated Reporting and Process Encapsulation

• Fast, Expandable, and Scalable

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Features

• Intuitive and easy to use software for performing fatigue analysis of finite element models

• Efficiently analyze large finite element models and complete usage schedules

• Wide range of fatigue analysiscapabilities including stress-life, strain-life, multi-axial, weld analysis, virtual shaker table, and more

• Highly configurable for the expert user

• Single environment for both Test and CAE data

• Enables automation of complete analysis processes and reporting

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Benefits

• Perform virtual durability assessment up front to reduce reliance on physical test and avoid costly design and tooling changes

• Perform smarter and quickerphysical tests by simulating first

• Design durability into your products and reduce warranty claims

• Assess more design options, consider more realistic loading conditions and more confidently reduce cost and weight

• Standardize analysis processes to improve consistency and quality

• Automate processes to better utilizeengineers’ time and workload

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Capabilities

• Stress-Life (single, multi-curve, Haigh diagrams)• Strain-Life (automated multi-axial corrections)• Notch sensitivity corrections• Seam welds and spot welds• High temperature corrections• Vibration fatigue (shaker simulation)• Multiple runs in a single analysis• Complete duty cycles / flight spectrums• Multi-processor enabled for fast results

• Finite Element results supported– Static– Direct Transient – Modal Transient– Harmonic

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Signal Processing Capabilities

• Function– Histogram Manipulation– Multicolumn Sort, Filter, Manipulation– Test Combination, Test Splitter– Units Conversion

• Digital Signal Processing– Calculators; Multicolumn, Time Series– Graphical Editor– Sample Rate Adjustment– Rainflow Counting, Amplitude Distribution– Filters; Butterworth, Fast Fourier– Frequency Spectrum– Operators; Arithmetic, Differentiation, Integration– Statistics, Running Statistics

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Integration in ANSYS Workbench

• DesignLife is a project page in Workbench• Page creation

– Select simulation or environment– Select option from DesignLife section of project page

• Materials assigned from parent simulation• Remaining setup completed in DesignLife page

– Load Mapping– Fatigue solver options

• Results from DesignLife solution included in the report• DesignLife accessible from DesignXplorer

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Engineering Data

• nCode material database converted to MATML• Extensions to Engineering Data

– Accept material formats• SN; Power law, Multicurve, Bastenaire• EN; Power law, Multicurve• Dang Van

– Allow Editing• Automatically mapped onto DesignLife model

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Engineering Data

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Frequency Based Fatigue Example

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DesignLife Vibration Fatigue

• Simulate vibration tests driven by random (PSD) or swept-sine loading

• More realistic and efficient than time-domain analysis for such applications

• Include static offset case• Consider duty cycles• Based on established

methods and militarystandards

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Vibration Fatigue Procedure

ANSYS Harmonic

FRF

FRF -AbsMax stress

FRF Critical plane

PSD

Swept Sine

PSD cycle counter *

Swept sine cycle counter

Static offset

principal

Offset critical plane

Rainflow cycle count (abs-max principal stress)

Rainflow cycle count

(critical plane stress)

LIFE*Dirlik, Lalanne, Steinberg, Narrow Band

COMPLEX

COMPLEX

REAL

ANSYS Static

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DesignLife Vibration Flow

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Validation Case Results

• Experimental results – B50 Life = 1680 s• Predicted mean life = 1660 s

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www.ncode.com

nCode InternationalTravelers Tower 126555 Evergreen RoadSuite 700Southfield, MI 48076Tel: (248) 350 8300Toll free: (877) 737 4242

Presented by Jeff Mentley

Email: jeff.mentley@nCode.comDirect: (248) 945 4368