Stress & Strength GmbH

Software for structural and system analysis

User Manual
LBF .WheelStrength Ophelia
®

3.33
Table of Contents

1 General Information .........................................................................................................5

1.1 About LBF®.WheelStrength.......................................................................................5
1.2 Structural Durability.....................................................................................................6
1.3 Technical Support .......................................................................................................7

2 Requirements ...................................................................................................................8
2.1 Soft- & Hardware Requirements .................................................................................8
2.1.1 Software Requirements .......................................................................................8
2.1.2 Supported FE-Solvers..........................................................................................8
2.1.3 Hardware Requirements .....................................................................................8
2.1.4 List of Tested Systems..........................................................................................9
2.2 Model Requirements .................................................................................................10
2.2.1 Nastran Input Deck.............................................................................................10
2.2.2 ANSYS Input Deck ............................................................................................10
2.2.3 Permas Input Deck.............................................................................................10
2.2.4 Finite Element (FE-) Model ...............................................................................10

3 Installing LBF®.WheelStrength.....................................................................................11
3.1 Extracting the Software..............................................................................................11
3.2 System Requirements................................................................................................11
3.3 Licence Settings.........................................................................................................11
3.3.1 Local Licence......................................................................................................12
3.3.2 Server Licence....................................................................................................12
3.4 Environment Variable.................................................................................................13
3.4.1 Linux...................................................................................................................13
3.4.2 Windows.............................................................................................................13
3.5 Starting LBF®.WheelStrength...................................................................................13
3.6 Setting Up a FE-Solver..............................................................................................14

4 LBF®.WheelStrength GUI ..............................................................................................15

4.1 Overview ...................................................................................................................15
4.2 The Menu Bar............................................................................................................16
4.2.1 File......................................................................................................................16

2
 4.2.2 Settings...............................................................................................................18
4.2.3 3D-View..............................................................................................................22
4.2.4 Help....................................................................................................................22
4.3 The Command Bar....................................................................................................23
4.4 The OpenGL Viewport...............................................................................................24
4.4.1 The OpenGL Toolbar..........................................................................................24
4.4.2 Navigation in the OpenGL Viewport...................................................................25
4.4.3 The Part Selection..............................................................................................26
4.4.4 The Cutting Tool.................................................................................................27

5 Biax Testing Method.......................................................................................................28

5.1 Biax Preprocessing....................................................................................................28
5.1.1 Model Data.........................................................................................................29
5.1.2 Vehicle Data.......................................................................................................29
5.1.3 Tire Data.............................................................................................................29
5.1.4 Load Application ................................................................................................30
5.2 Biax Load Cases........................................................................................................32
5.2.1 Standard Load Cases.........................................................................................32
5.2.2 User Defined Load Cases..................................................................................33
5.2.3 Design Spectrum................................................................................................34
5.3 Biax Evaluation Parameters......................................................................................35
5.4 Saving the Control File..............................................................................................36
5.5 Going through the Process........................................................................................36
5.6 Biax RFS Values........................................................................................................37
5.6.1 Results................................................................................................................37
5.6.2 Stress History Analysis Plots..............................................................................38
5.6.3 Report Generation..............................................................................................39

6 Radial Fatigue Testing (RFT) Method...........................................................................40

6.1 RFT Preprocessing....................................................................................................40
6.2 RFT Evaluation Parameters......................................................................................41
6.3 RFT RFS Values........................................................................................................41

7 Cornering Fatigue Testing (CFT) Method.....................................................................42

7.1 CFT Input Deck..........................................................................................................42

3
 7.2 CFT Preprocessing....................................................................................................42
7.2.1 Model Data.........................................................................................................43
7.2.2 Excitation Rod Fixation.......................................................................................43
7.2.3 Fixation Definition...............................................................................................44
7.2.4 Excitation Rod Fixation.......................................................................................44
7.3 CFT Evaluation Parameters......................................................................................45
7.4 CFT RFS Values........................................................................................................45

8 WSt-Results.....................................................................................................................46
8.1 Required Local Fatigue Strength...............................................................................46
8.2 Nodal Stress Histories...............................................................................................47
8.3 Nodal Local Spectra..................................................................................................48

9 Literature..........................................................................................................................49

4
1 General Information

1.1 About LBF®.WheelStrength

LBF®.WheelStrength is a specialized software for component characterization and

optimization as well as for service life approval of wheels for passenger cars and trucks.
Before producing expensive prototypes LBF ®.WheelStrength helps in a qualified way to
identify critical areas and to save material at non-critical areas. The first version came out
in 2002 as a plugin for Patran/Nastran, followed by a plugin for ANSYS. Both utilized the
biaxial testing method.
The new release of LBF®.WheelStrength brings its own GUI to enter the parameters and to
evaluate the results. Additionally to the biaxial testing method, the standardized testing
methods RFT (Radial Fatigue Test) and CFT (Cornering Fatigue Test) are offered. New
functions are introduced to support the user in his work. LBF ®.WheelStrength cooperates
with the FE-solvers ANSYS, Nastran and Permas and at the moment two tire models are
offered. One model represents a standard tire e.g. for passenger cars and the other model
represents a tire for a heavy truck.
To conduct a calculation a Nastran (*.BDF), ANSYS (*.CDB) or Permas (*.DAT.GZ) input
deck is required. This input deck will be loaded into LBF ®.WheelStrength. The software
guides the user through the needed input data and generates the applied loads. Spectra
can be created for the LBF Standard Cycle or for a user defined cycle.
When all input is defined the FE-solver can be called from within the LBF ®.WheelStrength
GUI. After the solver is finished the software reads the FE-results and performs the
damage calculation. At the end of this process a RFS value (Required Fatigue Strength)
for every node is available. These values can be plotted in color over the model of the
wheel. Additionally there is the possibility to generate plots for different parts of the cycle
and for single steps of the calculation, which can be displayed in color over the model.
For further evaluation stress history plots or spectra plots can be generated for single
nodes and saved as a picture. Other tools support to create a report of the performed
calculation or to cut the model into two parts, which can be displayed separately to have a
better view on the inside of the model.
One great advantage of this process compared to older versions is the performance. The
current version needs just a fraction of the time a past version would need for the same
damage calculation, due to higher efficiency.

5
1.2 Structural Durability

Structural durability deals with the assessment of the design, dimensioning and service life
of components and structures in the presence of mechanical loads. In the case of
LBF®.WheelStrength these components are wheels and hubs. Since these components
are safety-relevant, they must not fail in normal operation.

The user enters the material properties and the geometry and the software generates
loads to estimate the service life. In contrast to conventional FE-analysis – in which
tensions are investigated – LBF®.WheelStrength calculates RFS values (Required Fatigue
Strength). RFS values indicate which tension a component has to withstand at a certain
point without causing a crack within the desired service life.

6
1.3 Technical Support

If you need help using a Stress & Strength GmbH software product, we encourage you to
refer to the technical documentation first. If you need further assistance, please do not
hesitate to contact our technical support.
We can assist you in using product features, checking code errors, program installation,
and in using other software (e.g. ANSYS) in a general manner related to our software
product.
If you contact us, please give us information about your system, the used software
products and a detailed description of the problem, e.g. including log files.

CONTACT INFORMATION

You can contact our technical support by telephone, fax, or email.

Stress & Strength GmbH

Technical Support
Bartningstraße 47
D-64289 Darmstadt, Germany

Phone: (+49) - 6151 - 96 73 1 - 0

Fax: (+49) - 6161 - 70 58 396
Email: support@s-and-s.de

Regular business hours:

Monday to Thursday: 8 a.m. to 4 p.m.
Friday: 8 a.m. to 2 p.m.
(Central European Time)

7
2 Requirements

2.1 Soft- & Hardware Requirements

2.1.1 Software Requirements

Supported operating systems:

• Linux 64-bit • Windows 32-bit and 64-bit

The installed graphic driver should be the latest version and supporting OpenGL.
An installation of Java 1.7 or higher is necessary. The current version can be found under:
http://www.java.com/en/ . The LBF®.WheelStrength GUI needs a working Java Virtual
Machine, a working Java Development Kit in a current version is recommended.

2.1.2 Supported FE-Solvers

List of FE-solvers and versions that were tested:

 Nastran: MSC.Nastran 2012.2

 ANSYS: ANSYS 13, ANSYS 14, ANSYS 14.5, ANSYS 15

 Permas: Permas V14

2.1.3 Hardware Requirements

For RAM and other hardware-related requirements for the FE-solver program, please see
the related installation and configuration guide of this FE-solver. Additionally to the space
required by your FE-process you will need 3 GB RAM for LBF®.WheelStrength
postprocessing and at least 30 GB free hard disk. To work with big models with a high
number of nodes 8 GB RAM are recommended.

Hint: In some cases (e.g. memory errors while calling the solver) it might be useful
to end LBF®.WheelStrength after Load Application is done and to run the
FE-solver externally. When the calculation is finished the FE-solver can be closed
to have more memory available for the LBF®.WheelStrength Damage Calculation.

8
2.1.4 List of Tested Systems

Windows XP 32-bit, Service Pack 3

Nvidia Quadro FX 540
Intel Pentium 4, 3.00 GHz, 3 GB RAM

Windows 7 64-bit, Service Pack 1

Nvidia Geforce 9800 GT
Intel Core 2 Quad, 2.33 GHz, 3 GB RAM

Windows 7 64-bit, Service Pack 1

AMD Radeon HD 7700 Series
AMD FX-4100 Quad-Core, 3.60 GHz, 4 GB RAM

Windows 8
Intel HD Graphics 4600
Intel Core i5, 3.10 GHz, 8 GB RAM

Debian Stable, Kernel 3.2.0-4-amd64

AMD Radeon HD 6400M/7400M Series, driver fglrx 8.98.2
Intel Core i5, 3.20 GHz, 8 GB RAM

Redhat Enterprise Linux 6, Kernel 2.6.32-358.el6

Nvidia Geforce 9800 GT, driver nvidia 340.58
Intel Core 2 Quad, 2.33 GHz, 3 GB RAM

Ubuntu Linux 14.04 LTS, Kernel 3.13.0-32-generic

AMD Radeon HD 7700 Series, driver fglrx 2:13.350.1-0ubuntu2
AMD FX-4100 Quad-Core, 3.60 GHz, 4 GB RAM

9
2.2 Model Requirements

2.2.1 Nastran Input Deck

For Nastran the standard input deck format is used (*.bdf, *.dat).

2.2.2 ANSYS Input Deck

For ANSYS the used input deck file format is the ANSYS APDL-file (*.cdb, *.inp).

2.2.3 Permas Input Deck

For Permas the standard input deck format is used (*.dat.gz).

2.2.4 Finite Element (FE-) Model

To perform a calculation with LBF®.WheelStrength the following is required:

 The FE-model of the wheel has to be generated by FE solid elements, usually

10-node tetrahedron elements.

 One of the three global Cartesian axes has to be the global rotation axis of the
wheel FE-model. There should not be any node on the global rotation axis.

 Nodes must be numbered from 1 to n, here n is the number of nodes in the model.
Unreferenced nodes must be deleted.
n
 At least one displacement boundary condition has
Hint: Please notice that the
to be defined.
element or property groups,
 A linear elastic material definition (including the which exist in the preproces-
modulus of elasticity and the Poisson’s ratio) has sor during the model-building,
to be assigned to the FE solid elements. aren't always written auto-
 The used units are Millimeter and Newton matically into the input deck.

 To receive an optimal load application, there must be circumference node lines

(circumference element border lines) in the areas of inner and outer rim. For more
detailed information please have a look at chapter 5.1.4.

 A fixation has to be defined.

10
3 Installing LBF®.WheelStrength

3.1 Extracting the Software

For Windows an install wizard supports extracting the files. Linux users receive a zip-file
with the directory structure of LBF ®.WheelStrength. This file can be extracted to a desired
location.
In some Linux distributions it is necessary to set the execute permissions for the
executable files of LBF®.WheelStrength manually. This affects the executable files in the
folder wstengine and startWSt in the main folder of the LBF ®.WheelStrength directory
structure. To ensure that LBF ®.WheelStrength can work without any problems, please
check if these files are allowed to execute as program.

3.2 System Requirements

Please check that you have the latest graphic driver version and that it supports OpenGL.
Additionally a version of Java 1.7 or higher has to be installed. For the
LBF®.WheelStrength GUI a working Java Virtual Machine is required. Make sure, that you
use 32-bit Java on a 32-bit operating system and 64-bit Java on a 64-bit operating system.

3.3 Licence Settings

Before LBF®.WheelStrength can be used the licence has to be set up. Here we distinguish
between a local (node-locked) licence and a server (floating) licence. In both cases the
entries in the file settings.txt (see figure 3.1) in the folder settings have to be correct.
In case of a server licence the server has to be installed before. To perform this the server
setup has to be executed and after that the licence file
Hint: This can also be helpful,
licence.txt has to be copied into the main folder of the
if the operating system
LBF®.WheelStrength server directory structure. The
stopped the service for
licence server is ready for use after a restart or after the
various reasons.
service Wst Server has been started manually.

11
 Figure 3.1: LBF®.WheelStrength settings.txt

3.3.1 Local Licence

If the install wizard is used, these entries are set automatically. Please verify:

LicLocal: true
LicFile: <direction of the licence file>
LicKeyPath: <direction of the key files (standard: „settings“-folder)>
(ending with separator)

It is advised to put the licence file licence.txt into the folder settings.

3.3.2 Server Licence

The server has to be installed as described above. The IP address and the port number of
the LBF®.WheelStrength licence server are required now. Following entries in the file
settings.txt on the client have to be adapted:

LicLocal: false
LicIP: <IP address of the LBF®.WheelStrength licence server>
LicPort: <port of the LBF®.WheelStrength licence server>
LicKeyPath: <direction of the key files (standard: „settings“-folder)>
(ending with separator)

The user needs to have write permissions for settings.txt.

12
3.4 Environment Variable

An environment variable has to be set for LBF ®.WheelStrength.

3.4.1 Linux

The start script startWSt in the main folder of the LBF®.WheelStrength directory has to be
adapted. For that it needs to be opened in a text editor. Only the first line has to be
changed. Here the main folder of the LBF ®.WheelStrength directory has to be specified:

export WSTPATH= <main folder (without separator at the end)>

3.4.2 Windows

If the install wizard is used, the environment variable is set automatically. Please verify:

In Windows XP:
Control Panel → System → Advanced → Environment Variables

In Windows 7:
Control Panel → System and Security → System → Advanced System Properties
→ Advanced → Environment Variables

The new environment variable is called WSTPATH and it's value has to be the main folder
of the LBF®.WheelStrength directory (without separator at the end).

3.5 Starting LBF®.WheelStrength

LBF®.WheelStrength can now be started by opening the file startWSt.bat (Windows) or the
file startWSt (Linux).

13
3.6 Setting Up a FE-Solver

Figure 3.2: LBF®.WheelStrength Settings FE-Solver Tab

To enable the FE-solver calling from within the LBF ®.WheelStrength GUI the settings
dialog (Settings → Preferences) has to be opened on the tab FE- Solver (see Figure 3.2).
Here the executable has to be selected.
Please find following some examples, filename and directory can differ at your system.

Nastran: \MSC.Software\MSC.Nastran\bin\nast20051.exe
ANSYS: \ANSYS Inc\v140\ansys\bin\intel\ANSYS140.exe
Permas: \INTES\V14\bin\permas.bat

LBF®.WheelStrength is now set up and you are prepared to create your first project.

14
4 LBF®.WheelStrength GUI

4.1 Overview

LBF®.WheelStrength is divided into three parts:

 Preprocessing (incl. FE-solution)

 Postprocessing

 Utilities (supporting tools)

The automatic LBF®.WheelStrength pre- and postprocess can be started when the data
input is completed.

15
4.2 The Menu Bar

The menu bar (see figure 4.2) has under File, Settings, 3D-View and Help a menu
structure which is described in the following.

Figure 4.2: Menu Bar

4.2.1 File

New Project … : Creates a new project for LBF®.WheelStrength. A new window comes up
where specific project data can be entered (see figure 4.3).

Figure 4.3: Create New Project

• Project Name: The name of the project. The control file and the written input decks

16
 will bear this name.

• Project Path: The folder where all LBF®.WheelStrength project files will be written.

• Date: The current date is shown in this field. A custom date can be defined, if
necessary.

• Model Format: The format of the original input deck. Choosing the model format
also sets the corresponding usable FE-solver.

• Solver: The FE-solver is automatically selected by selecting the model format.

• Mesh File: The original input deck.

• Testing Method: The testing method of the current project has to be selected.

• Author: The Username is entered automatically. The user can change the name.

Load Project … : Opens an existing LBF®.WheelStrength

project created on the same PC. The project has to have
the same directory it had after creating. Hint: When you already
worked on a project and want
Import Project … : Imports a LBF®.WheelStrength to create or open another
project, which has been created on a different PC. The project, it is advised to restart
control file within the project folder that has been copied LBF®.WheelStrength before.
from another computer has to be selected. The path This can increase the per-
setting is changed corresponding to the current location formance and prevent errors.
inside the control file, or a new control file is created.
This is also necessary after moving or copying the
project to another directory.

Input Deck Conversions: Offers the possibility to convert the input deck to a compatible
format for particular solvers. To make the input deck compatible with Femap
Write Femap Input Deck is used.

Export Results … : Offers the possibility to export the RFS values in a format, which allows
operating with them in other software. LBF ®.WheelStrength supports exporting to
Patran 2.5 Nodal Results Files and to IDEAS Universal Files.

17
4.2.2 Settings

Language: Sets one of the installed languages.

Preferences: Opens the dialog WheelStrength Preferences where the user has the
possibility to adjust LBF®.WheelStrength. The Save button is used to apply the made
changes. With the Load button the user can reset all settings to the state of last saving.
The preferences are divided into four tabs – Licence, FE-Solver, Display and Extra – which
are discussed in the following.
On the top is the Licence tab (see figure 4.4). Here the licence type can be selected. We
distinguish between a local licence and a server licence. If Local Licence is selected, the
location of the licence file has to be set. If Server Licence is selected, the server IP
address and port number have to be entered. The Key Path is needed for both types of
licences.

Figure 4.4: LBF®.WheelStrength Preferences Licence Tab

The FE- Solver tab (see figure 4.5) helps setting the FE-solver location. To enable the
FE-solver calling from within the LBF ®.WheelStrength GUI the executable has to be
selected. Additional settings regarding the FE-solvers can also be set.
For Nastran there are the following extra options: You can select a scratch directory by
selecting the checkbox Scratch and entering the directory. To use the standard directory of
Nastran please don't check. The base memory can be set by selecting the checkbox
Memory and entering the memory value in Megabytes. If your processor supports
Hyperthreads select the checkbox. The geometry test can be turned off by selecting

18
Geomcheck None. To allow Nastran to ignore non-critical errors select the checkbox
Bailout -1. For models with more than 150 000 nodes ..
Hint: The number of proces-
please check Add 'NASTRAN SYSTEM(151)=1'. In case
sors should only be entered,
the number of cores Nastran uses should be set, please
if the solver licence allows it.
check Number of Processors and enter the wished
number.

Figure 4.5: LBF®.WheelStrength Preferences FE-Solver Tab

Femap users should check Load Application and Read FE Results for Femap to be able to
use the Start All functionality of the command bar. LBF ®.WheelStrength then automatically
converts the input deck after Load Application is done to a format which is usable for
Femap. Show Nastran Version Information is also a feature for users of Femap. If it is
activated at every start of LBF®.WheelStrength a message is shown, which reminds the
user of the particularities of this solver.
For further settings of Nastran please have a look at the corresponding user manual.
To call ANSYS or Permas from within the LBF ®.WheelStrength GUI the executable of the
used solver also has to be selected. For ANSYS there is the possibility to turn the

19
geometry test off by checking Turn Off ANSYS Element Shape Check. For a certain
ANSYS Working Directory please select the checkbox and enter the directory. This is
necessary to be able to use the Start All functionality of the command bar. In case the
number of cores ANSYS uses should be set, please check Number of Processors and
enter the wished number.
Permas users have the possibility to generate displacement data in the Permas results file
by checking Generate Displacement.
For further settings of ANSYS or Permas please have a look at the corresponding user
manual.

The Display tab (see figure 4.6) controls settings for the OpenGL viewport. The different
colors for the load application rings can be changed here, as well as the model color, line

20
color, the color a picked node is displayed with and the size of nodes and axes. The color
of an object is changed by clicking into the respective colored field.
The Pick Color is the color of a picked node after selecting. The Live Pick Color is the color
a node is displayed with, when the node selection mode is activated and the mouse
pointer is over this node. The Pick Tolerance of the node selection can also be adapted
here. More about the node selection and the navigation in the OpenGL viewport can be
found in chapter 4.4.2. To enable selecting of midnodes, which are on the lines between
the regular nodes, please check Also Select Midnodes. With the function Show Axis Text

the axes in the OpenGL viewport can not only be identified by their color but also by their
coordinates (see figure 4.7). The Cartesian axes can be displayed centrally in the OpenGL

(see figure 4.8) Show Axis Info in Legend has to be checked. There is the possibility to
hide the maximum values of the different colors in the legend by disabling

21
Show Legend Text (see figure 4.8). When Show Fixation is checked, every node of the
Fixation is highlighted in the Fixation Color. Checking the checkbox Show Info in 3D-View
induces that project name and testing method are displayed in the OpenGL viewport and
also in screenshots and reports (see figure 4.9).
In the Extra tab there is the possibility to set up the PDF reading software, which enables
the user to open this manual through the LBF ®.WheelStrength menu.

Java Memory Control: The used and available memory for the Java Virtual Machine can
be reviewed (see figure 4.10). Please note that the FE-solver also has to be able to
allocate enough memory. In some cases it might be useful to end LBF ®.WheelStrength
and run the FE-solver externally to have more memory available for the FE-process.

Figure 4.10: Java Memory Control

Show Model Information: Shows some information about the input deck, e.g. number of
elements, nodes or materials.

Toggle Display Test: Test to verify that the system supports OpenGL. It is positive when a
square is displayed in the viewport. When the system does not support OpenGL nothing
happens.

4.2.3 3D-View

Here the user has access to all functions of the OpenGL toolbar (refer to chapter 4.4.1).

4.2.4 Help

About: Shows some information about the software, e. g. version or copyright holder.

View Manual: Opens this manual.

22
4.3 The Command Bar

Figure 4.11: Command Bar

With the command bar the user has access to the different steps of the
LBF®.WheelStrength procedure. Buttons of already performed steps are green like
Save Controlfile in figure 4.11. If the letters of the Start All button and Call FE-Solver are
gray like above, no solver is enabled in the settings. There is also an indicator for the
status of the software on the left. If a process is running the wheel is blue and turning,
otherwise it is gray and fixed.
The command bar offers access to the following commands:

Save Controlfile: Saves the controlfile with the current information you have entered.
Before you can start Load Application, the control file has to be saved.

Start All: Starts the whole process. It calls Load Application, Call FE-Solver and
Damage Calculation one after another.

Load Application: Starts the preprocessing. Make sure that all required information for the
process has been entered and saved in the controlfile.

Call FE- Solver: If the FE-solver is set in the preferences, it can be called from within the
LBF®.WheelStrength GUI. The FE solver can also be called externally or be used from a
different computer. In that case the FE-results file has to be copied into the
LBF®.WheelStrength project folder.

.
Damage Calculation: Reads the FE-results from the
Hint: If the FE-solver was
used FE-solver and puts the needed information in
used externally it is recom-
unified files usable for the LBF ®.WheelStrength
mended to move or copy the
postprocessing. After that the postprocessing is
FE-results into the project
performed and the damage calculation results are color-
folder before.
plotted in the OpenGL viewport.

23
4.4 The OpenGL Viewport

4.4.1 The OpenGL Toolbar

The OpenGL toolbar (see figure 4.12) provides the user control over the OpenGL viewport.
The below listed functions are available. These functions can also be accessed through
the menu bar.

 Centers the model and zooms to a level that shows the whole model.

 Rotates the model to an isometric view.

 Rotates the model to a front view.

 Rotates the model to a side view.

 Rotates the model to a top view.

 Takes a screenshot of the current OpenGL viewport.

 Toggles the axes on and off.

 Toggles the color legend on and off.

 Toggles between model view, ring view and hybrid view.

 Clears the output area.

 Opens the part selection of the model.

 Opens the cutting tool.

 Cancels the node selection mode.

24
4.4.2 Navigation in the OpenGL Viewport

The mouse is used to navigate in the OpenGL viewport. The model can be moved by
clicking the right mouse button. Zooming can be achieved by scrolling or using the slider
below the OpenGL viewport. Quick zooming can be achieved by holding the control key on
the keyboard and scrolling with the mouse. By holding the shift key on the keyboard it is
possible to draw with the left mouse button a zoom box in the viewport.
To select a node the left mouse button is used. When the node selection mode is activated
– e. g. by clicking into a text field in which a node has to be entered – a square appears
behind the mouse pointer (blue square in figure 4.13). This square represents the node

That will be selected by clicking the left mouse button in

Hint: Though midnodes are
this moment. An already selected node is marked by a
not displayed in the viewport,
square in a different color (here red). In which color and
they can be selected, if it is
size these squares are displayed can be changed in the
enabled in the Preferences.
Display tab of the Preferences (refer to chapter 4.2.2).

25
Near to every text field in which a node has to be entered is a slider to adapt the
Pick Tolerance. This slider is useful to simplify the selection of nodes in coarser or finer
meshed areas. The Pick Tolerance can also be set up in the Display tab of the
Preferences.
When one node has been selected a new window opens giving more information about
this node. ID and position of the selected node are shown as well as its RFS value.

4.4.3 The Part Selection

For models with more than one group of nodes the part selection (see figure 4.14) can be
used to display the different parts separately. This is also useful after working with the
cutting tool.

To display only one part of the model select this part in

Hint: The part selection also
the list and press OK. Selecting All_Parts and pressing
supports multiple selection. If
OK effects that the whole model is displayed again.
you want to display not all
The name of a part can be changed by Rename. Using parts, but more than one,
this button opens the Rename window (figure 4.15). In select them by using the
this window the original name of the part is displayed control key on the keyboard.
and the new display name can be entered below. The
original name does not change after renaming and the display name can be anytime reset
to the original name again using the Reset button.

26
4.4.4 The Cutting Tool

The cutting tool (see figure 4.16) can be used to create cuts through the model. It gives the
user the possibility to verify how the stresses are distributed inside of the model.

Figure 4.16: Cutting Tool

To locate the cut through the model, a node and a plane have to be selected. When node
and plane are chosen, the cut can be created by pressing the Create button. For every cut
two parts of the model are created and displayed in the list in the cutting tool window.
These parts are added to the part selection of the model. To have a look on the created
parts, they can be selected by pressing the button for part selection on the OpenGL
toolbar. Its node number and plane can be found in the name of every part.
The Save button is used to create a file in the project folder which describes the cuts.
Saved cuts are loaded as well when the project gets loaded again. A part of the model can
be removed from the list by pressing the Delete button.
Pressing Cancel closes the cutting tool window.

27
5 Biax Testing Method

5.1 Biax Preprocessing

Figure 5.1: Biax Preprocessing Input

28
Figure 5.1 shows the tab of preprocessing input for the biaxial testing method.
Preprocessing information is necessary for the creation of all relevant unit load cases and
for the definition of calculation steps, which will be used for further calculation in the
LBF®.WheelStrength process.
For correct results, the boundary conditions must have been defined and applied to the
wheel.

5.1.1 Model Data

The global rotation axis needs to be set first. The mouse rotation and the calculation of the
necessary cylinder coordinates depend on the rotation axis. Please note that the model
needs to have one of the global axes as the wheel rotation axis.

5.1.2 Vehicle Data

First select the base vehicle: Passenger Car, Light Truck, Heavy Truck or User Defined
can be chosen. Then select the operation: LBF Design Spectrum for predefined load
cases and load cycles developed by the Fraunhofer LBF in Darmstadt or User Defined to
set up your own load cases describing a custom load cycle.
The design life depends on the chosen vehicle and operation. The user can also enter a
custom value. The design life for biaxial testing is entered in kilometers.

5.1.3 Tire Data

Select a tire model from the list. In most cases the standard tire model is sufficient. The tire
dimensions are entered using the ECE R30 and ECE R54 guidelines. First the tire width in
millimeters is entered, then the height-width-ratio in percent and finally the wheel diameter
in inches.
The tire pressure can be entered in kilopascal, bar or psi. Please note that usually 15 %
are added to the actual tire pressure in the text field to correspond to the Zwarp testing.
Upon entering the rated wheel load in the Vehicle Data section, the tire spring rate is
calculated. This tire spring rate is an approximation. If the actual tire spring rate is given, it
can be entered in the corresponding text field by checking the checkbox
Enter tire spring rate.

29
5.1.4 Load Application

Four nodes need to be selected for the representation of the four load application rings
(see figure 5.2). The Ring Tolerance can be adapted for finer or coarser meshed models.

Figure 5.2: Biax Load Application Rings

These rings are needed to transform the loads on the tire to loads that the wheel

Figure 5.3: Loads from Tire to Wheel

30
 -
experiences (see figure 5.3 and figure 5.4). The nodes
Hint: As a reference for the
can be chosen by selecting the text field and then
distance between the nodes
selecting a node inside the OpenGL viewport. If the
we suggest two degrees for a
nodes are known, they can also be entered by keyboard.
wheel (180 nodes per ring)
The OpenGL toolbar has a button to show the selected
and four degrees for a hub
rings. The rotation axis and the form of rings can be
(90 nodes per ring).
validated. It is recommended that all load application
-
rings have the same number of nodes.

Figure 5.4: Circumferential Node Lines

A polygon shaped ring (figure 5.5) can occur if the Ring Tolerance is set too fine or if the
rotation axis or the node is chosen wrongly. Stepping (figure 5.6) – visible by zooming -
can occur if the Ring Tolerance is too coarse. Recommended is a value of 0.1.

Figure 5.5: Polygon Figure 5.6: Stepping

Before proceeding to the next tab, make sure that none of the upper cases apply and save
the entered data by clicking the Save button.

31
5.2 Biax Load Cases

5.2.1 Standard Load Cases

The load cases represent the used load spectrum. The standard biaxial load spectrum
depends on the LBF Standard Cycle. It is a combination of straight driving and cornering
load cases (see figure 5.7). The user has the possibility to create custom load cases
representing a custom application.

At first the forces of the load cases are needed. If the selected operation is
LBF Design Spectrum, the Proposed Values button can be used to fill in the standard

32
values which depend on the rated wheel load. Every load case has a positive vertical force
and a positive and negative lateral force. Please note that the LBF Design Spectrum does
not include any negative lateral forces for cornering into the calculation process.
By pressing the Edit Spectrum Values button it is possible to adapt the spectrum.

5.2.2 User Defined Load Cases

For the operation User Defined there is the possibility to create up to six custom load
cases representing custom applications as seen in figure 5.8.

33
5.2.3 Design Spectrum

The spectrum data has to be entered as ratios (see figure 5.7 and 5.8). The following
ratios are needed to define the spectrum: H/Ht, Hn/Ht, He/H. Also the form has to be
defined. It is defined by the parameter n1, which is 1 for a linear distribution and 2 for a
Gauss distribution.

Definition of frequencies:
Ht : Total frequency (design life / rolling circumference)
H : Total frequency of individual spectrum of the physical load case
Hn : Frequency of rolling under static wheel load
He : Frequency of extreme load conditions

These values can be exported or imported to or from an external LBF ®.WheelStrength file.

The entered data has to be saved by clicking the Save button before continuing to the next
tab.

34
5.3 Biax Evaluation Parameters

The user has the possibility to create several evaluation areas if needed (see figure 5.10).
An evaluation area has specific characteristics depending on its material. If the wheel only
has one material, then one evaluation area describing that material is sufficient.

Figure 5.10: Biax Evaluation Parameters

Every area is identified by its name entered in the Area Name field. If the whole wheel is

35
only one area, please select Global as Area Characteristics. For different areas, you can
choose specific Area Characteristics like Rim, Disc or others.
One or both of the Stress Hypothesis have to be selected. Usually both can be selected
and compared later.
Generic Material Data can be selected by the dropbox. Given materials have certain
values for the S-N-Curve and the Haigh Diagram. If a material is needed that is not listed,
please select User Defined to enter custom values describing the used material.
After all inputs are made the area is created by pressing the Create/Update button.

5.4 Saving the Control File

If all inputs have been done and saved, the control file has to be saved as well. It contains
all information that has been entered. The control file will be saved in the project folder and
is named [projectname].txt.
After the biax preprocessing a new control file [projectname]_biax.txt will be created,
including the loads.

5.5 Going through the Process

After all the input is done and the control file is saved there are two ways the process can
be started. Start All starts the whole process step by step from the beginning to the end. If
an error occurs in a specific step this could complicate troubleshooting. Another way is to
start the different steps individually from Load Application to Damage Calculation.
These are the necessary steps for a LBF®.WheelStrength calculation:

 Filling in the three input tabs (Preprocessing, Load Cases, Evaluation Parameters)

 Save Controlfile
Hint: In some cases it might
 Load Application
be useful to run the FE-solver
 Call FE-Solver externally (see chap. 2.1.3).
 Damage Calculation
Start All covers the steps from Load Application to Damage Calculation.

36
5.6 Biax RFS Values

The RFS Values tab (figure 5.11) is used for viewing results, creating plots and generating
a report if required.

5.6.1 Results

By pressing Set the entered Maximum RFS Color Value can be applied. This changes the
maximum of the color legend and so the colors which represent the different values. With
the Get button the actual maximum value is applied and inserted into the text field.

37
By checking the checkbox Show RFS Values the plot of the RFS color values over the
wheel can be activated or deactivated. If both stress hypotheses – Major Principle Stress
and von Mises Stresses – have been selected for the test method, it is possible to switch
between the RFS values of the two results. The plot in the OpenGL viewport is adjusted
accordingly. The checkbox Show Wireframe is used to toggle the wireframe over the plot.

5.6.2 Stress History Analysis Plots

The stresses on a node can be evaluated in a plot. The ...

user can either enter the node or use the pick Hint: Please notice that
functionality by selecting the text field and then selecting ANSYS does not provide
the desired node by the mouse. If only one results for midnodes. In this
Evaluation Area exists, it is automatically selected. For case generating plots for a
multiple evaluation areas the one that matches to the midnode will cause an error.
node has to be selected.

Figure 5.12: Plot Window for Selected Node

38
By clicking on Generate Plots a new window will pop up with the spectra and stress history
plots (see figure 5.12). You can switch between the two plots by selecting the
corresponding tab. In the Options menu there is the ...
Hint: To be able to generate
possibility to adjust the plot properties and also to export
plots for projects that were
them as PNG images. The exported images will be
created and calculated with a
saved in the project folder.
previous version of
The last information in this section is Min RFS Value and ®
LBF .WheelStrength the
Max RFS Value occurring in the model. By pressing evaluation area has to be
Show the node with the minimum or maximum RFS updated by pressing
value gets selected. If the selection can not be seen, Create/Update in the tab
increasing the Pick Node Size in the Display tab of Evaluation Parameters.
Preferences will resolve this.
More information regarding the plots can be found in chapter 8.

5.6.3 Report Generation

For a report with screenshots of one or more specific nodes please add this or these
nodes to the list. The entered or selected node can be added to the list by clicking
Add Node. The selected node in the list can be removed by Remove Node.
The checkbox Automatic Inner/Outer Screenshots gives Hint: Please notice that the
the possibility to use screenshots of the wheel in the automatically created screen-
report which are made by the software automatically, or shots are also made of the
to make custom screenshots for the inner and outer OpenGL viewport with its
wheel. These can be created by the two buttons below current size. They can still be
the checkbox and capture the current view in the affected by resizing the
OpenGL viewport. If one button is clicked more than viewport.
once the last screenshot will be used in the report. For a
screenshot of a node please select it in the list and then use the button
Take Node Screenshot. The last screenshot of each node will be added to the report.
When all screenshots are made, the report can be generated by clicking the button
Generate Report. The report and all pictures will be saved in the report folder in the project
directory.

39
6 Radial Fatigue Testing (RFT) Method

6.1 RFT Preprocessing

40
The Preprocessing input tab for the RFT method (see figure 6.1) is very similar to the one
for the biaxial testing method. The applied force is defined by the Rated Wheel Load and a
Load Factor. To receive the applied force these two values are multiplied. For details
regarding the required data, please refer to the following specifications:

– SAE J2530

– EUWA ES 3.11

– AK-LH 08.
Just as the biaxial testing method, the RFT method ...

needs a tire model. Also the boundary conditions as well Hint: Please notice that
as the elastic modulus and Poisson ratio have to be set LBF®.WheelStrength sim-
in the input deck. ulates rolling on a plane in
opposition to the physical test
For the explanation regarding the different required
benches, which have an
inputs please see chapter 5.1. As the RFT method has a
external or internal drum.
specific load case, no load cases need to be set up and
there is no load case tab.

6.2 RFT Evaluation Parameters

The evaluation areas are set up the same in all testing methods (refer to chapter 5.3).

6.3 RFT RFS Values

If all inputs have been done and saved, the control file has to be saved as well and the
process can be started (refer to chapter 5.4 and 5.5).
The RFS Values tab is used for viewing the results. More details can be found in chapter
5.6. The only difference is, that for the RFT method there are only stress history plots and
no spectra plots.

41
7 Cornering Fatigue Testing (CFT) Method

7.1 CFT Input Deck

For the CFT method the input deck should not have a fixation, as the fixation is done
automatically during the process. Please note, that an extra node is placed on the rotation
axis representing the excitation rod. The loads will be applied on this node.

7.2 CFT Preprocessing

Figure 7.1: CFT Preprocessing Input

The Preprocessing tab for the CFT method (see figure 7.1) is different than in the other
testing methods. One main difference is, that for CFT no tire is used.

42
7.2.1 Model Data

The global rotation axis has to be selected. This affects the rotation of the model. Make
sure to set this first.

7.2.2 Excitation Rod Fixation

First Node and Second Node represent two rings. All nodes between those two will be
selected. These will represent the connection to the excitation rod. By clicking on Show, all
used nodes are shown to verify the input (see figure 7.2). The color of the selected nodes
can be changed in the Settings menu under Preferences in the Display tab. It has to be
selected whether the excitation rod is in the positive or negative direction.

Figure 7.2: Selected Nodes for Excitation Rod

By clicking Show again, the nodes will be hidden. The last required node is a node
representing the ring used for fixation purposes.

43
7.2.3 Fixation Definition

The in the input deck predefined fixation can be used, but LBF ®.WheelStrength can also
generate a fixation over up to four fixation rings. In the second case the existing fixation in
the input deck is deleted.

7.2.4 Excitation Rod Fixation

The CFT Moment that is applied in Nm can be entered. In this case the length of the
Lever Arm is set to 700 mm.
If desired the CFT Moment and the length of the Lever Arm can be calculated based on
different parameters. The Dynamic Rolling Radius can also be calculated based on the
Tire Dimensions. For details regarding the required data, please refer to the following
specifications:

– SAE J2530

– EUWA ES 3.11

– AK-LH 08.

The CFT Moment is calculated as follows: M = S * fvstat * (rdyn * µ + ET)

M: Maximum Bending Moment [Nm]

S: Accelerated Test Factor

fvstat: Static Wheel Load [N]

rdyn: Dynamic Rolling Radius [m]

µ: Coefficient of Friction Hint: To represent an offset

please use a negative inset
ET: Inset [m]
value.

The calculation steps describe how many steps per excitation rod revolution are used. The
CFT method uses the Number of Cycles instead of a km value for the design life.

44
7.3 CFT Evaluation Parameters

The evaluation areas are set up the same in all testing methods (refer to chapter 5.3).

7.4 CFT RFS Values

If all inputs have been done and saved, the control file has to be saved as well and the
process can be started (refer to chapter 5.4 and 5.5).
The RFS Values tab is used for viewing the results. More details can be found in chapter
5.6. The only difference is, that for the CFT method there are only stress history plots and
no spectra plots.

45
8 WSt-Results

8.1 Required Local Fatigue Strength

The LBF®.WheelStrength main result is the Required Local Fatigue Strength (RFS). These
nodal values are calculated in the following way:
From the nodal stress time histories for one revolution under the extreme physical driving
conditions the maxima and minima are used to calculate amplitudes and mean stresses.
The stress amplitudes are transformed according to the Haigh diagram to a stress
amplitude with a stress ratio of R = -1. These values are used to set up local sub spectra
of the distinguished physical load conditions. During the subsequent damage calculation
these sub spectra are superimposed to the design spectrum at each calculation area. By
iteration to the allowable damage sum the RFS at the knee point of the S-N curve is
calculated for each node. These results can subsequently be evaluated by test results in
which cracks had occurred in individual areas. Additionally, together with selected nodal
stress time histories, which show the relative damage related to the physical driving
conditions, it is possible to work out against which physical load cases a redesign is
necessary. Different wheel areas show different fatigue strength mainly influenced by the
manufacturing, so in the end not a fatigue life but a required fatigue strength is calculated.
Figure 8.1 below shows an example for the RFS result of a whole wheel and the definition
of the RFS value as the required fatigue strength at the knee point of the S-N curve.

Figure 8.1: RFS Values on the Wheel and on the Woehler Curve

The example shows that critical and uncritical areas are clearly visible. Consequently it is
possible to work out areas for redesign. With a subsequent new LBF ®.WheelStrength
calculation the redesigned component can be easily calculated.

46
8.2 Nodal Stress Histories

Nodal stress histories can be created for each node of the defined evaluation areas. The
stress histories are shown in a Java plot (see figure below).

Figure 8.2: Nodal Stress History Plot

Additionally, the selected equivalent stress, the RFS value and the relative damage related
to the physical driving conditions are integrated in the XY plot.
By the means of the RFS plot the critical areas are pointed out and stress time histories of
the relevant nodes can be created to work out the possibilities of improvements or other
alterations for redesign. The revolution angle of 180 degrees defines the center of wheel
loads and the different physical load cases are defined in the legend.

47
8.3 Nodal Local Spectra

As a feature you are able to generate nodal local spectra plots. An example is given in
figure 8.3.

Figure 8.3: Nodal Local Spectra Plot

The x-axis represents the cycle life and the y-axis the equivalent stress (stress value after
mean stress transformation) in MPa. Additionally, the S-N curve with its knee point iterated
to the RFS value is shown. The plotted spectra are cornering, straight driving and – in
case you processed the operation condition – triax trailer shunting.

In the specified literature (see chapter 9) the LBF ®.WheelStrength methods and results are
elaborated in more detail.

48
9 Literature

Grubisic, V.; Fischer G.:

„Methodology for Effective Design Evaluation and Durability Approval
of Car Suspension Components”
SAE Paper 970094 (1997)
Rupp, A.; Heinrietz, A.; Ehl, O.:
„Simulation of the Experimental Proof Out of Wheels and Hubs”
SAE 2002-01-1202 (2002)
Heinrietz, A.; Lehrke, H.-P.; Rupp, A.; Barthel, C.:
”Identification of Parametric Tire Models for the Fatigue Evaluation of
Suspension Components”
SAE 2003-01-1276 (2003)
Ehl, O.; Simms, P. ; Störzel, K. ; Bruder, T.:
”Reliable pre-design of commercial vehicle rotating suspension components”
SAE 2003-01-3426 (2003)
Ehl, O.; Lhomme, J.; Heinrietz, A.; Boscarato, G.:
”Numerical pre-design of run flat system wheels on the example of Michelin’s
PAX System”
6th International User Meeting Biaxial Wheel/Hub Test Facility (2003)
Heim, R. ; Fischer, G. ; Sonsino, C. M.:
“Early Stage Rig Testing for Durability Approval”
SAE 2005-06M-324 (2005)

Further literature can be found in the given papers.

49