Time domain fatigue analysis in LS-DYNA R12

DYNAmore Nordic Webinar

2020-10-01

Marcus Lilja, Senior Engineer

marcus.lilja@dynamore.se

Copyright © 2020 DYNAmore Nordic AB

Agenda
■ Fatigue solvers in LS-DYNA
■ Time domain fatigue solver - Compatibility
■ Time domain fatigue solver – Flow chart
■ Time domain fatigue solver – Keywords
■ Time domain fatigue solver – Materials
■ Time domain fatigue analysis – What is needed?
■ Example – Notched bar
■ Last words
■ Useful sites - User support

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Fatigue solvers in LS-DYNA

LS-DYNA 971 R5

VIBRATION SOLVER *FREQUENCY_DOMAIN_..._FATIGUE

SSD, RANDOM VIBRATION, …

*MAT_ADD_FATIGUE d3ftg

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Fatigue solvers in LS-DYNA
LS-DYNA R12!

VIBRATION SOLVER *FREQUENCY_DOMAIN_..._FATIGUE

SSD, RANDOM VIBRATION, …

*MAT_ADD_FATIGUE d3ftg

GENERAL SOLVER
Explicit, Implicit, Thermal, … Time domain *FATIGUE

Introduction of a time domain fatigue solver!

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Time domain fatigue solver – Compatibility
■ Fully coupled by stress/strain computations to solvers
■ SMP and MPP
■ Linux and Windows
■ Manufacturing effects can be considered
■ Easy integration with LS-OPT / LS-TASC (TBD!!)

Solid EM

IGA
Fatigue &
Stress / Strain
Meshless Element failure
computation
FSI analysis

Peridynamics Thermal

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Time domain fatigue solver – Flow chart

Stress / strain Output: d3ftg

calculation

Restart Neuber’s equation Rainflow counting

Initial fatigue?

mean stress
Stress / strain Fatigue
cycles calculation
S-N / E-N curves

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Time domain fatigue solver - Keywords
■ The time domain fatigue solver is activated by including the
*FATIGUE_{OPTION}-keyword.
■ Available keywords in R12 are:

R12!

R12! Additional keywords used in fatigue analysis:

*INITIAL_STRESS_{OPTION}
*INITIAL_FATIGUE_DAMAGE_RATIO
*MAT_ADD_FATIGUE

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Time domain fatigue solver - Keywords
■ *FATIGUE_{OPTION}
■ To activate solver
■ OPTION=D3PLOT or ELOUT is needed!

BINARY=2
on *DATABASE_ELOUT!

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Time domain fatigue solver - Keywords
■ *FATIGUE_LOADSTEP
■ To define fatigue cycles, single or multiple
■ Unique exposure time for each step
■ Exclude part of solution

B
A

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Time domain fatigue solver - Keywords
■ *FATIGUE_MEAN_STRESS_CORRECTION
Mean stress introduction by:
- Prestress
- Thermal load
- Gravity load
- Residual loads
- …

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Time domain fatigue solver - Keywords
■ *FATIGUE_MULTIAXIAL
■ To account for multiaxial cyclic loading
Example:
■ Multiplane-methods The stress state at a hole is always mutiaxial
■ Critical plane F (t ) = sin (22  t )
■ …
Default

Multiaxial

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Time domain fatigue solver - Keywords
■ *INITIAL_FATIGUE_DAMAGE_RATIO_{OPTION}
■ Option = D3FTG or D3PLOT

*INITIAL_FATIGUE_DAMAGE_RATIO_D3FTG

Cumulative damage ratio Failed/safe zone

Expected fatigue life Expected fatigue life, log10 scale

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Time domain fatigue solver - Keywords
■ *INITIAL_FATIGUE_DAMAGE_RATIO_{OPTION}
■ Option = D3FTG or D3PLOT

The d3plot option may be used to

include damage from GISSMO-models
or other transient preload cases.

Cumulative damage ratio

Expected fatigue life Expected fatigue life, log10 scale

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Time domain fatigue solver - Keywords
■ *FATIGUE_SUMMATION
■ To read in fatigue damage(d3ftg) defined by *INITIAL_FATIGUE_DAMAGE_RATIO
and sum the damages to a total.

Cumulative damage ratio from transient

preload + fatigue load
Damage from transient preload Damage ratio from fatigue load *INITIAL_FATIGUE_DAMAGE_RATIO and
case (d3plot) *FATIGUE_SUMMATION

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Time domain fatigue solver - Materials
■ *MAT_ADD_FATIGUE - for S-N data (low stress, high cycle)

N Sm = a
log( S ) = a − b  log( N )

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Time domain fatigue solver - Materials
■ *MAT_ADD_FATIGUE_EN - for E-N data (high stress, low cycle)

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Time domain fatigue solver - Materials
■ *MAT_ADD_FATIGUE – Coming features

The value represents mean stress or temperature or …

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Time domain fatigue solver – Output results
■ *DATABASE_D3FTG
■ Fringe plot of fatigue results

Cumulative damage ratio Failed/safe zone

*FATIGUE_D3PLOT & smp only today

Expected fatigue life Expected fatigue life, log10 scale

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Time domain fatigue solver – Output results
■ Fatigue results available
■ Cumulative damage ratio
■ Expected fatigue life
■ Expected fatigue cycles
Also
■ Log10 scale of fatigue life
■ Failed/safe zones

Cumulative damage ratio Failed/safe zone

Expected fatigue cycles

Expected fatigue life Expected fatigue life, log10 scale

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Time domain fatigue analysis – What is needed?

Model & Load case

*CONTROL_... *FATIGUE_D3PLOT/ELOUT
*DATABASE_...
*NODE
*ELEMENT_...
*SECTION_..
*PART_...
*MAT_...
*MAT_ADD_FATIGUE Fatigue results!
*LOAD_... (Matched by MID)
*…
*…
…

*DATABASE_D3FTG

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Time domain fatigue analysis – What is needed?
From this point you can choose to further refine and/or add on features to the
fatigue analysis.

Model & Load case

*FATIGUE_D3PLOT/ELOUT
*CONTROL_...
*DATABASE_...
*NODE
*FATIGUE_MULTIAXIAL
*ELEMENT_...
*SECTION_.. *FATIGUE_...
*PART_...
*MAT_...
*MAT_ADD_FATIGUE
(Matched by MID)
Fatigue results!
*LOAD_...
*… *FATIGUE_LOADSTEP
*…
…
*DATABASE_D3FTG

*FATIGUE_MEAN_STRESS_CORRECTION

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Example – Notched bar
■ In this example the restart option is not used.
■ It is then suggested that the fatigue-keywords are defined in a separate ‘run-file’, fatigue.k

stress.k fatigue.k
*CONTROL_... include *FATIGUE_ELOUT output
*DATABASE_... *DATABASE_D3FTG D3FTG
*NODE *MAT_ADD_FATIGUE
*ELEMENT_...
*SECTION_..
*PART_...

*FATIGUE_ELOUT
*MAT_...
*LOAD_...
*…
*…
…

binout (incl. elout)

1. Run fatigue.k to get d3ftg results

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 Example – Notched bar
■ In this example the restart option is used.
■ It is then suggested that the fatigue-keywords are defined in a separate ‘run-file’, fatigue.k

Remove ELOUT-output!
stress.k *CONTROL_...
*CONTROL_... *DATABASE_...
Copy stress.k
*DATABASE_... *NODE fatigue.k
*NODE *ELEMENT_...
*SECTION_.. *INCLUDE *FATIGUE_ELOUT output
*ELEMENT_... D3FTG
*PART_... *DATABASE_D3FTG
*SECTION_..
*MAT_... *MAT_ADD_FATIGUE
*PART_...
*MAT_... *LOAD_...
*LOAD_... *…
*… *…
*… …
…

binout (incl. elout)

2. Copy stress.k and remove 3. Run fatigue.k to get d3ftg results

1. Run stress.k to get binout file
The ELOUT-history from the file

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Example – Notched bar
■ Model
■ ELFORM = -1
■ *MAT_ELASTIC

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Example – Notched bar
■ Load case
■ Fixed BC
■ Fully reversed loading (no mean stress influence)

Load

Fixed (SPC)
Termination time = 8 s

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Example – Notched bar
■ Fatigue set-up
Stress based Restart with ELOUT-data

Max. principal stress

*FATIGUE_D3PLOT & smp only today

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Example – Notched bar
■ Fatigue material data log-log interpolation S-N amplitude

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Example – Notched bar
■ Run stress.k
■ Check binout/elout

Element id: 129514

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 Example – Notched bar
■ Copy stress.k

Copy of stress.k

binout in run-directory! ELOUT not active!

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Example – Notched bar
■ Run fatigue.k
■ View results in D3FTG

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Example – Notched bar *FATIGUE_LOADSTEP

■ D3FTG

TSTART = 0.0 TSTART = 0.0

TEND = 4.0 TEND = 8.0

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Last words
■ Fatigue analysis of models containing…
■ Contacts
■ High order elements
■ Rubbers
■ Prestress
■ Inteference
■ Initial stress/force
… is now possible!

Courtesy of
Kongsberg
Automotive, Thule
Sweden, Swisslog,
Volvo GTT and
Dellner Couplers

Copyright © 2020 DYNAmore Nordic AB

Useful sites - User support
■ support@dynamore.se
■ Customer support
■ www.dynaexamples.com
■ LS-DYNA example-models for different disciplines
■ www.dynalook.com
■ Papers from LS-DYNA User’s conferences
■ www.dynamore.se/en/training/seminars
■ Seminar and Webinar schedules

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 Thank you!

Your LS-DYNA distributor and

more

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