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Multidisciplinary Fatigue Workflows

using the Simulia Portfolio

October 2016

Mark WyattBusiness Development ExecutiveSIMULIA, Fatigue and Durability

DS SIMULIA Corp.

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SIMULIA’s Power of the Portfolio

Predict and Analyze Product Life

• Fatigue Analysis

• Durability Prediction

• Fatigue Analysis

• Durability Predictionfe-safe

Process Automation & Design Optimization

Isight• Design/Runtime Gateway

• Application Components

• Process Drivers

• Design/Runtime Gateway

• Application Components

• Process Drivers

Continued Technology Leadership & Innovation

More Physics, Open Co-Simulation

Abaqus

• Abaqus/CAE

• Abaqus/Standard

• Abaqus/Explicit

• Abaqus/CFD

• CEL, FSI, SPH, EMAG

• Abaqus/CAE

• Abaqus/Standard

• Abaqus/Explicit

• Abaqus/CFD

• CEL, FSI, SPH, EMAG

Non-parametricDesign Optimization

Tosca• Structural & Fluid Flow Optimization

• Conceptual & Detailed Design

• Topology, Sizing, Shape, Bead Optimization

• Structural & Fluid Flow Optimization

• Conceptual & Detailed Design

• Topology, Sizing, Shape, Bead Optimization

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Extended Packaging

SIMULIAExtended Package

Licensing

fe-safe

Abaqus

Tosca

(struc+fl)

Isight

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Andy and Laura� Retired couple from Bay Area,

CA;

� Love to travel to Flagstaff, AZ.

� Andy: 64, health good; hip implant

from osteo-arth. initiated in auto

accident (control arm bushing

failure) in 1975. Loves to ride his

motorcycle.

� Laura 62, health good; some

heart issues. Arterial stents

solved main issues. Loves fly

fishing.

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Bushing workflow

fe-safe/Rubber

fatigue analysisAbaqus

stress analysisAbaqus

stress analysis

Isight parametric

optimization

Tosca nonparametric

shape optimization

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Controller approach to reduce stress concentration

Shape optimization using Tosca

� Design surface: free surface

� Constraint

� Stamping constraint: two bean shaped holes

� Symmetric constraint: all design nodes

� Freeze constraint: nodes tied to the rigid bodies

� Mesh smoothing

� Objective

� Minimize damage value:

where N is number of cycles to fatigue

1

log�

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Optimization results

• Worst life in number of cycles

increase from 6833 to 13662

(~99.9%)

• Number of iterations: 12

• Cost: 2 hr 23 min with 1 CPU

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Validation fe-safe runs before and after shape optimization

Fatigue analysis of a rubber bushing

• Worst life improved from 6833 cycles to 13662 cycles (~99.9% increase)

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Bushing workflow

fe-safe/Rubber

fatigue analysisAbaqus

stress analysisAbaqus

stress analysis

Isight parametric

optimization

Tosca nonparametric

shape optimization

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Imagine

Workbench testing of 200 variants

���� Certification in 60 days

Virtual testing through SIMULATION

Each variant takes less than 5 min

Workbench testing of one variant: 12 days

���� Certification in less than 2 weeks

200 variants 200 variants

40 test machines 1 test machine

ISO 7206/4, ASTM F2996-13

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Design of Experiments to automatically generate, test, and evaluate all variants

Isight Process Automation

� Execute ISO 7206/4 virtual testing for all variants in a couple of hours

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Isight Workflow: fe-safe

Virtual Testing with Isight

� fe-safe fatigue analysis

�Run fe-safe fatigue analysis

� Uses Abaqus FEA results

� automatically executed within Isight workflow

�Life results

� Worst Life Repeats

� Factor of Strength (FOS) plots

Abaqus ParallelUp to 60%Token

usage reduction

In Isight

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Isight Workflow Execution

Virtual Testing with Isight

� Overall virtual testing takes just a couple of hours on a standard workstation

� Virtual testing with Abaqus and fe-safe takes less than 5 minutes per variant

� Fatigue life using shape optimization was increased 4.8 times

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ReliabilityAnalysis

Stress AnalysisNon-Parametric

Design Optimization

Parametric Design

Optimization

Fatigue Life

Fatigue Life

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ReliabilityAnalysis

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Reliability Analysis on Stents

� The thickness of the artery presents the

largest source of uncertainty in the

model

� Radii with +/- 2.5% variation assumed

�Outer – 1.62 mm mean and 0.02784 mm

SD

� Inner - 1.132 mm mean and 0.018 mm

SD

Inner

Radius

Outer

Radius

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Reliability Analysis on Stents Response Surface

(fe-safe)

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This workflow illustrates how SIMULIA Portfolio can help engineers

redesign motorcycle brake rotor geometry towards more reliable,

lightweight and durable design

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Process to Accelerate Innovation

Conceptual lightweight design

Topology Optimization

- Tosca Structure

Insured reliability

Durability Analysis

- fe-safe

Understand physical behavior

Structural & Thermal Analysis

- Abaqus

Exploration of design alternatives

Parametric Optimization

- Isight

Improved structural integrity

Shape Optimization

- Tosca Structure

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Results Comparison

Durability Analysis

� After shape optimization:

�More rounded shape

�Less gradient

�Life is longer

(infinite life design was achieved)

�Higher Factor of Strength (1.4)

FOS

Initial Optimized

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Jing Bi

George Ang

Gergana Dimitrova

Jiang Yao

Manoj Chinnakonda

Manuel Biedermann

Sandy Eyl

Yangwook Cho

Robert Combier

Steven Ribeiro-Ayeh

Pawel Sobczak

Jegan Chinnaraju

Michael Werner

Cheryl Liu

Joe Haemer