FiSiBLE STaTE

Product Development and Support Innovation Cycle R&D

Fatigue Life Analysis

Fatigue Life Analysis

Metal fatigue analysis evaluates the impact of cyclic loads on the structural life of a product to ensure it
meets requirements for performance, quality, and safety. Actually fatigue analysis uses the Stress Life
Method to predict the high cycle fatigue life of metallic components experiencing either variable
amplitude loading (Rainflow counting) or constant amplitude loading (Cumulative Damage Theory-
Miners Rule).

Use the results to validate your product while you are designing, in order to:

Quickly and efficiently adjust designs to meet the required product life
Establish recommended maintenance schedules, including part replacement
Minimize failures, reduce warranty costs, and maximize product life
Fatigue is the process of component failure due to cyclic loading, and generally the nominal stresses
in a component are elastic—below the material yield point. The fatigue process consists of initiation,
propagation, and fracture; and the time for a crack to initiate and grow to cause component failure is a
function of the component material strength and the stress field.

Fatigue Analysis can be performed based on results of static studies, as well as frequency domain events
from linear dynamic harmonic and linear dynamic random vibration studies.

The material strength is defined and data plotted in the form of a “stress to number of cycles to failure”
(S-N) curve.

The results of a fatigue analysis are given in terms of:

Life plot—shows the number of cycles (for constant amplitude event studies) or the number of blocks (for
variable amplitude studies) that causes fatigue failure at each location
Damage plot—shows the percentage of the life of the structure consumed by the defined fatigue events
Factor of safety (FoS) plot—shows the load FoS for fatigue failure at each location
Biaxiality indicator—Plots the ratio of the smaller alternating principal stress (ignoring the alternating
principal stress nearest to zero) divided by the larger alternating principal stress
Matrix charts—for variable amplitude studies

Fatigue Analysis

It is observed that repeated loading and unloading weakens objects over time even when the induced
stresses are considerably less than the allowable stress limits. This phenomenon is known as fatigue.
Each cycle of stress fluctuation weakens the object to some extent. After a number of cycles, the object
becomes so weak that it fails. Fatigue is the prime cause of the failure of many objects, especially those
made of metals. Examples of failure due to fatigue include, rotating machinery, bolts, airplane wings,
consumer products, offshore platforms, ships, vehicle axles, bridges, and bones.

Linear and nonlinear structural studies do not predict failure due to fatigue. They calculate the response
of a design subjected to a specified environment of restraints and loads. If the analysis assumptions are
observed and the calculated stresses are within the allowable limits, they conclude that the design is safe
in this environment regardless of how many times the load is applied.

Results of static, nonlinear, or time history linear dynamic studies can be used as the basis for defining a
fatigue study. The number of cycles required for fatigue failure to occur at a location depends on the
material and the stress fluctuations. This information, for a certain material, is provided by a curve called
the SN curve.

Stages of Failure Due to Fatigue

Failure due to fatigue occurs in three stages:

Stage 1 One or more cracks develop in the material.

Cracks can develop anywhere in the material but
usually occur on the boundary faces due to higher
stress fluctuations. Cracks can occur due to many
reasons. Imperfections in the microscopic
structure of the materials and surface scratches
caused by tooling or handling are some of them.
 Stage 2 Some or all the cracks grow as a result of
continued loading.

Stage 3 The ability of the design to withstand the applied

loads continue to deteriorate until failure occurs.

Fatigue cracks start on the surface of a material. Strengthening the surfaces of the model increases the
life of the model under fatigue events.

As the alternating stress gets

smaller, the material can take
more stress cycles before it fails
due to fatigue. The endurance
limit is the highest alternating
stress that does not result in
fatigue failure. In other words, if
the alternating stress is equal to
or lower than the endurance
Endurance Limit limit, the number of stress
cycles to cause failure becomes
very large (practically infinite).
The endurance limit is usually
defined for zero-mean
alternating stresses. The
endurance limit is also called
the fatigue limit. Some metals
do not have a measurable
endurance limit.

Alternating Stress The alternating stress is defined

as |(σmax – σmin)| / 2 where σmax
and σmin are the maximum and
minimum stresses respectively.
 In Simulation, you can set the
stress component to calculate
the alternating stress as: the
Stress intensity (P1 – P3), the
equivalent stress (von Mises), or
the maximum absolute
principal stress (P1).

Stress Range Stress = (σmax – σmin)

Mean stress = Sm = (σmax +

Mean Stress
σmin)/2

Stress Ratio Stress ratio R = σmin/σmax

Fatigue life, at a given

alternating stress level and
Fatigue Life mean stress, is the number of
cycles required to cause failure
due to fatigue.

Number of cycles where the

fatigue strength ceases to
decrease. In other words, the
Infinite Life
number of stress cycles required
to cause failure is practically
infinite.

The stress at which fatigue

Fatigue Strength failure occurs after a given
number of loading cycles.
Stress- Life Cycle (S-N) Curve

Fatigue strength is determined by applying different levels of cyclic stress to individual test specimens
and measuring the number of cycles to failure. The graphical representation of fatigue data points is the
cyclic stress amplitude or alternating stress (S – vertical axis) versus the number of cycles to failure (N –
horizontal axis). Fatigue strength is defined as the stress at which fatigue failure occurs at a given
number of cycles. A typical S-N curve is shown below.

Usually the base 10 logarithm of number of cycles N is used instead of N due to the typical large range of
N values. In SolidWorks Simulation, you can choose from three interpolation schemes to locate
intermediate data points on an S-N curve: Log-Log, Semi-Log, and Linear. For examples of SN
Interpolation schemes, see SolidWorks Simulation Help: Example of SN Interpolation Schemes.
Specimens are tested in a series of decreasing stress levels until no failure occurs within a selected
maximum number of cycles (usually 10 million cycles). The nearly horizontal portion of the curve defines
the fatigue or endurance limit for the test material. If the applied stress amplitude is below the
endurance limit of the material, the specimen is said to have aninfinite life. For many non-ferrous metals
and alloys such as aluminum, magnesium, and copper alloys, however, there will not be a definite
endurance limit and the low stress portion of the curve will not converge to a horizontal line. These
materials instead display a continuously decreasing S-N curve.

An S-N curve for a material defines cyclic stress amplitudes (or alternating stress) versus the number of
cycles required to cause failure at a given stress ratio R. Stress ratio R is defined as the ratio of the
minimum cyclic stress over the maximum cyclic stress. For a fully reversed loading, R = -1. When the
loading is applied and removed (not reversed), R=0.
 Fully-reversed Load, R = -1 Zero-based Load, R = 0

Experimental results have shown that the mean stress has a significant impact on the fatigue resistance
of a specimen. For any material, you can define multiple S-N curves (up to ten) where each S-N curve
corresponds to a different stress ratio R. The software then uses linear interpolation between the S-N
curves to extract data for a given stress ratio.

When one S-N curve with stress ratio R = -1 (fully-reversible or zero-mean stress) is used to define the
fatigue properties of a material, you can select a correction method (Goodman, Gerber, or Soderberg) to
account for the effects of non-zero mean stresses.
S-N curves are based on mean fatigue life or a given probability of failure. Generating an S-N curve for a
material requires many tests to statistically vary the alternating stress, mean stress (or stress ratio), and
count the number of cycles to failure.

Tests to generate S-N curves are performed under a controlled loading environment. In most cases, the S-
N curves are obtained from uniaxial loading on fully-reversed stress cycles. Since the actual loading
environment is generally multi-axial, you may need to reduce the fatigue strength. The software provides
the Fatigue strength reduction factor in the Fatiguedialog box to account for this discrepancy.
Associating S-N Curves to a Material

To solve a fatigue study, you need to define S-N curves for each material applied to your model. You can
enter alternating stress – cycle data to define a new S-N curve, or you can use an existing S-N curve from
the material database. S-N curves are only used for fatigue studies.

Some materials in the material library have S-N curves already assigned. These material are identified by
an (SN) suffix at the end of their names in the list box. The reference of the SN curves is the Atlas of Fatigue
Curves, ASM International.

Materials with stress-strain curves are identified by (SS), and materials with both SN curves and stress-
strain curves are identified by (SS,SN).
To assign an S-N curve to a material:

1. In a Fatigue study, add a fatigue event.

2. In the Material dialog, on the Fatigue SN Curves tab, in the Source box do the following:
1. For Interpolate, set the scheme for interpolating alternating stresses against the number of cycles
of the S-N curve.
2. Select Define and select a curve from the list. Curves that are already defined have the stress ratio
value attached to their names (for example R = -1). Curves that are not defined are tagged as (Not
Defined). Select an undefined curve to populate with data.
You can define up to 10 S-N curves for different values of stress ratios R to a specific material.
3. In the Table data box, do the following:
1. In the Stress ratio (R) box, enter the stress ratio associated with the curve.

R = Smin / Smax, where Smin is the minimum

Stress Ratio stress in the stress cycle and Smax is the
maximum stress.

Mean Stress Smean= (Smax + Smin) / 2

2. Set the unit of stress.

3. Populate the curve data by entering Alternating Stress values versus number of cycles to failure
due to fatigue, or click File to import data from the Simulation S-N Curve library.
To import curve data points stored in a (*.dat) file, click File in theFunction Curves dialog.The
format of the curve data points File (*.dat)should have two columns: Number of Cycles (first
 column) andAlternating Stress (second column).
To add a new row, double-click the last cell under the Points column.

To delete a row, highlight it and click the Delete key or right-click it and select Delete.

4. Click View to graph the data or Save to save the curve to a data file(*.dat).
Preview box shows the curve as it is defined.

5. Type a source of reference for the SN curve data in Source.

4. Click Apply.

Interpolation between S-N Curves

When an S-N curve for a specific stress ratio is not available, the program linearly interpolates between S-
N curves to extract data for a specific stress ratio.

Suppose you have defined only two S-N curves in the material database for a given material for stress
ratios 0.5 and 1.0. Based on your analysis, you want to calculate the number of cycles N for stress ratios
0.25 and 0.7.

The program interpolates linearly between the S-N curves defined for specific stress ratios, if the
calculated stress ratio falls in the range of the defined stress ratios. For example, for the calculated stress
ratio of 0.7, the program calculates N1 from the first curve and N2 from the second curve. It interpolates
linearly between N1 and N2 to find the number of cycles N for stress ratio 0.7.

It the stress ratio falls outside the range of the given S-N curve stress ratios, then the S-N curve with the
closest stress ratio is considered. In the above example, the stress ratio 0.25 falls outside the range of the
defined ratio 0.5 to 1.0. The S-N curve with the closest stress range is 0.5, and therefore, the first curve is
considered in the computation of the number of cycles.

In the absence of multiple S-N curves for a specific material, you can use a single S-N curve with a stress
ratio of -1 (zero-mean stress ratio). To adjust the value from the zero-mean stress ratio curve to the actual
intended stress ratio (calculated from the actual stress conditions, apply one of the mean stress
correction methods (Goodman, Gerber, or Soderberg).

Mean Stress Correction

The alternating stress amplitude for a stress cycle is computed as half the stress range in the cycle. The
amount of damage caused by a stress cycle depends not only on the alternating stress but also on the
mean stress. For example, the two cycles below have the same alternating stress but because they have
different mean stresses, they cause different amounts of damage.

The effect of mean stresses on the cycles to failure is illustrated by the following diagram, called the
Haigh diagram.
The mean stress is zero only when the load is fully reversible. The most straightforward case is when an S-
N curve with the same R-ratio as the loading is provided. In this case, the S-N curve is directly used since
no correction is needed. If you define S-N curves with different R-ratios, the software accounts for the
mean stress by linear interpolation between the curves. If only one S-N curve with an R-ratio that is
different from the R-ratio of the loading is provided, a correction is needed.

The program always uses the von Mises stress to calculate the mean stress. Since von Mises is a positive
quantity, the program assigns the sign of the first mean principal stress to it for the purpose of calculating
the associated mean stress.
Definitions

To discuss correction methods, let us define the following variables for a stress cycle:

Smax = maximum stress

Smin = minimum stress

ΔS = stress range = Smax – Smin

Sa = alternating stress = (Smax – Smin)/2

Smean = mean stress = (Smax + Smin)/2

R = Stress ratio = Smin/Smean

A = amplitude ratio = Sa/Smean

The stress and amplitude ratios for some common loadings are listed:

Loading Type Stress and Amplitude Ratios

Fully reversed R = -1, A = infinity

Zero to maximum R = 0, A = 1

Zero to Minimum R = infinity, A = -1

Correction Methods
In the following let:

Sca = the corrected alternating stress (based on zero mean.),

Sy = yield stress, and

Su = ultimate strength

The software offers the following methods to calculate Sca:

Method Equation

1. Goodman method- generally suitable for brittle

materials:

2. Gerber method – generally suitable for ductile

materials

3. Soderberg method – generally the most

conservative

For both variable and constant amplitude events, the software calculates the mean stress in addition to
the alternating stress for each cycle and then it evaluates the corrected stress using the specified criteria.

Performing Fatigue Analysis

To perform fatigue analysis:

1. Create one or more static, nonlinear or modal time history dynamic studies.
2. Create a fatigue study (constant amplitude or variable amplitude) and define its properties. Make
sure to set the proper options before running the study.
3. Notice the events type shown with the name of the Loading folder in the Simulation study tree.
Right-click theLoading folder and select Add Event to define a fatigue event based on a reference
 static study, or on a particular solution step from a nonlinear or modal time history dynamic study. To
define a fatigue event based on multiple reference studies, set Loading Type to Find Cycle Peaks.
Variable amplitude events usually contain large amount of data. The Function Curve dialog lets you
import text files containing the data as load history curves. The data become available when defining
a variable amplitude fatigue event.
4. You must define at least one SN curve for each material. Click the Fatigue SN Curvestab in the
Material dialog box to define SN curves.
5. Right-click Result options and select Define/Edit to request results at all nodes or at boundary nodes
only. If the study is based on variable amplitude events, you can request the Rainflow matrix chart at
the desired locations.
6. For variable-amplitude fatigue studies, right-click a fatigue event icon and select Plot 3D Rainflow
matrix or Plot 2D rainflow matrix to plot a chart for the bins of the input load history
7. Run the fatigue study.
If the results of a reference study, used in defining an event, are not available, the program runs the
reference study automatically before running the fatigue study.

8. Set the fatigue study analysis options. Right-click the topic icon and click Properties. See help topic
Fatigue Analysis Options for more information on the fatigue options.
9. View results:
Double-click an icon in a results folder to display the associated plot.
To define a plot, right-click the Results folder and select the Define Fatigue Plot.
To list results, right-click the Results folder and select List Fatigue Results.
For studies with variable amplitude events, right-click the Results folder and select Define Matrix
Charts to view Matrix Charts.
Click here for more result viewing options.

If you run a study before meshing it, the program meshes the study automatically before running it.
You can also request to run the study by checking Run analysis after meshing in the Mesh
PropertyManager.
When you run a study that does not have any result folders, the software creates the folders and plots
specified in the Result Options for the study type. If result folders are present, the software updates
the existing plots.

Fatigue Events

The software handles two different types of fatigue events: constant amplitude and variable amplitude.
You can also define multiple fatigue events, and set the type of interaction between them to: no
interaction or random interaction between events. The random interaction method is based on the ASME
Boiler and Pressure Vessel Code. The software mixes peak stresses from different events to evaluate the
alternating stress.

Constant Amplitude Events

All cycles of a constant amplitude event have the same alternating and mean stresses. A constant
amplitude fatigue event is fully defined by an alternating stress, mean stress (or stress ratio), and the
number of cycles.

A fatigue event can be based on:

A single load case from a static study, or from a particular solution step of a nonlinear or modal time
history dynamic study.
Multiple load cases from static studies or from solution steps of a nonlinear or modal time history
dynamic studies. In the case of multiple load cases, the software determines the load case
combination that produces the largest stress fluctuation.

Example of Constant Amplitude Event

Variable Amplitude Events

A variable amplitude fatigue event is a load history record that defines the fluctuation history of a load.
The time values do not play any role for fatigue studies with a single variable amplitude event. In this
case, it is adequate to define the amplitude sequence. For studies with more than one variable amplitude
fatigue events, time values are needed for each record to correlate to other loading events.

Number of Repeats

Add Event (Constant) PropertyManager

The Add Event (Constant) PropertyManager allows you to define a constant amplitude event for a fatigue
study.
You can set up a fatigue event based on a single load case or several load cases from multiple reference
studies. The fatigue loads can refer to one or more static studies, or to a particular solution step of a
nonlinear or time history linear dynamic study.

Load

No. of Cycles Sets the number of cycles

associated with this event.

Loading Type Sets the type of fatigue loading

to determine the stress peaks
and hence the alternating
stress. Alternating stress =
|maximum stress – minimum
stress|/2, where | | denotes the
absolute value.

Fully The fatigue

reversed (LR event is
= -1) based on one
reference
study. All
loads, and
 hence stress
components,
in the
reference
study change
their
magnitudes
proportionall
y from their
maximum
values as
specified by
the reference
study to zero.

Zero-based The fatigue

(LR = 0). event is
based on one
reference
study. All
loads, and
hence stress
components,
in the
reference
study change
their
magnitudes
proportionall
y from their
maximum
values as
specified by
 the reference
study to zero.

Loading ratio The fatigue

event is
based on one
reference
study. Each
load, and
hence each
stress
component,
in the
reference
study
changes its
magnitude
proportionall
y from its
maximum
value (Smax)
to a
minimum
value defined
by R*Smax,
where R is
the load
ratio. A
negative
ratio
indicates
reversal of
the load
direction.
Loading
ratio .
Enter a
loading
ratio.
Fatigue
loads are
said to be
proportio
nal when
the
directions
of
principal
stresses
for each
node are
identical
for all the
reference
studies
that you
use in
defining
fatigue
events. In
all other
cases, the
fatigue
loads are
said to be
non-
proportio
nal.
Find Cycle The fatigue
Peaks event is
based on
several load
cases. The
program
calculates the
alternating
stresses for
each node by
considering
the
combination
of peaks from
different
fatigue loads.
It then
determines
the
combination
of loads that
produces the
largest stress
fluctuation.

The fatigue
loads can
refer to one
or more static
studies, or to
a particular
solution step
 of a
nonlinear or
linear
dynamic
time history
study.

Study Association Sets the reference studies.

Study
counter.

Select Find
cycle peaks to
continue
defining up
to 40 load
No.
cases.
Double-click
in theNo. cell
to add a row.
All studies
must have
the same
mesh.

Study. Sets the

reference
study. Click in
this cell to
select a study
from the
drop-down
menu. For a
 references
study, you
can select a
static study,
or stress
results from a
particular
solution step
of a
nonlinear or
linear
dynamic
study.

The list of
studies
includes the
studies that
are
associated
with the
currently
active
configuration
only.

Scale. This scale

factor lets
you define a
fatigue event
based on a
reference
study with
scaled loads.
Since the
study is
linear, the
program uses
this factor to
scale the
stresses. You
cannot scale
loads defined
in a nonlinear
study.For
example, if
the reference
study has a
pressure load
of 50 psi
applied to a
face and you
want to
define a
fatigue load
based on 150
psi on the
same face,
you should
enter a scale
factor of
150/50 = 3.
The program
multiplies
the stress
results of the
reference
study by this
factor to
calculate
stress values
for use in
calculating
 alternating
stresses.

Sets the
solution step
for the
reference
nonlinear or
linear
dynamic
study. The
Step.
program uses
the stress
results of this
particular
step to
calculate the
alternating
stresses.

You can use the same study for

defining multiple fatigue
events.

Defining a Fatigue Event Based on a Single Load

To define a fatigue event based on a single load case, in the Add Event (Constant)PropertyManager:

1. Set the Number of Cycles associated with the fatigue event.

2. From the Loading Type menu , choose one of the following options:
Fully reversed
Zero based
Load ratio
 3. In the Study Association box :
1. Select a static, nonlinear or dynamic time history study in the first row. You can enter a scale
factor under Scale. The program multiplies the stress components of the reference study by this
factor to evaluate alternating stress values.
2. For a nonlinear or dynamic time history study, under Step enter a particular time step. The output
of this particular solution step is considered for the evaluation of alternating stress values.
4. Click .

Contents

Single Constant Amplitude Fatigue Event

A constant amplitude fatigue event is fully defined by an alternating stress, mean stress (or stress
ratio), and the number of loading cycles.

Defining a Fatigue Event Based on Multiple Load Cases

To define a constant amplitude fatigue event based on multiple load cases, in theAdd Event
(Constant)PropertyManager:

1. Set the Number of Cycles associated with the fatigue event.

2. Set Loading Type to Find Cycle Peaks .
3. In the Study Association box :
1. Select a static, nonlinear or dynamic time history study in the first row. You can enter a scale
factor under Scale. The program multiplies the stress components of the reference study by this
factor to evaluate alternating stress values.
2. For a nonlinear or dynamic time history study, under Step enter a particular time step. The output
of this particular solution step is considered for the evaluation of alternating stress values.
4. Insert a new row by double-clicking in the No column. Select a study and enter a scale factor. You can
enter up to 40 load cases.
5. Click .

The program evaluates at each node the differences in the stress component values for all possible
combinations of stress peaks and determines the load combination that produces the largest stress
fluctuation.
Contents
 Single Fatigue Event Based on Multiple Loads
The program calculates the alternating stresses for each node by considering the combination of
peaks from different fatigue loads. The fatigue loads can refer to one or more static studies, or to a
particular solution step of a nonlinear or time history linear dynamic study.

Add Event (Variable) PropertyManager

The Add Event (Variable) PropertyManager allows you to define a variable amplitude event for a fatigue
study. You can define multiple fatigue events for one fatigue study. A variable amplitude fatigue event
refers to one or more static studies, or to a particular solution step of a nonlinear or time history linear
dynamic study.

Load

Get Curve Opens the Load History Curve

dialog to define the curve data.
You can define the curve
manually or load a predefined
history.

The Simulation Curve library

includes sample Load History
curves from SAE.

View Graphs the load history curve.

Study Association Sets the reference static study.

No. Study
counter. Only
one study is
allowed for
each variable
amplitude
event.

Study. Click in this

cell to select
a study from
the drop-
down menu.
The list of
studies
includes the
studies that
are
associated
with the
currently
active
configuration
only.

The program
uses linear
theory.
Scaling
results is
invalid if the
static study
includes
nonlinear
effects such
as contact or
 large
displacement
s.

Use this scale

factor to
relate the
amplitudes
of the
variable load
history curve
to the load in
the study.
You cannot
scale loads
Scale.
defined in a
nonlinear
study.For
example if
the
amplitudes
are measured
in volts, the
scale factor
must relate
volts to the
load unit.

If the model is subjected to

multiple loads, define multiple
studies with one load in each
study. You can then define one
event for each load case with
the proper scale factor.

Option
 Number of Repeats. Repeats the curve data the
specified number of times.

Example:

No. of No. of
Repeats = 1 Repeats = 3

Event Start Time. Use this entry to time the

selected multiple events. This
input is ignored if you define a
single event for the study.

Example:

Event start Event start

time = 0 time = 50

Theory of Cumulative Damage

The theory of cumulative damage assumes that a stress cycle with an alternating stress above the
endurance limit inflicts a measurable permanent damage. It also assumes that the total damage caused
by a number of stress cycles is equal to the summation of damages caused by the individual stress cycles.

Linear Damage Rule

Assume that the S-N curve indicates that it takes N1 cycles at an alternating stress S1 to cause fatigue
failure, then the theory states that each cycle causes a damage factor D1 that consumes 1/N1 of the life of
the structure.

Moreover, if a structure is subjected to n1 cycles at S1 alternating stress and n2 cycles at S2 alternating

stress, then the total damage factor D is calculated as:

D = (n1/N1 + n2/N2),

where N1 is the number of cycles required to cause failure under S1, and

N2 is the number of cycles required to cause failure under S2.

This rule is referred to as the Linear Damage Rule or the Miner’s Rule. The damage factor, also called
usage factor, represents the ratio of the consumed life of the structure. A damage factor of 0.35 means
that 35% of the structure’s life is consumed. Failure due to fatigue occurs when the damage factor reaches
1.0.

The linear damage rule does not consider the effects of load sequence. In other words, it predicts that the
damage caused by a stress cycle is independent of where it occurs in the load history. It also assumes that
the rate of damage accumulation is independent of the stress level. Observed behavior indicates that
cracks initiate in a few cycles at high stress amplitudes, whereas almost all the life is spent on initiating
the cracks at low stress amplitudes.

The linear damage rule is used in its simple form when you specify that fatigue events do not interact
with each other in the properties of the study. When you set the interaction between events to random,
the program uses the ASME code to evaluate the damage by combining event peaks.

Multiple Fatigue Events

Evaluating alternating stresses for multiple fatigue events depends on whether the events occur
randomly or independently (no interaction between events). You can set the type of interaction between
multiple fatigue events in the Fatigue dialog box.
 No Interaction SolidWorks Simulation evaluates the alternating stress
separately for each event. Each fatigue event occurs
independently from the other events. The damage factors
from all events are added sequentially.

Random Interaction The software considers the possibility of mixing peak stresses
from different events for the evaluation of alternating
stresses.The software evaluates the maximum alternating
stress by considering all possible pairs of fatigue events at
each node. It then uses the Miner’s rule and the ASME Boiler
and Pressure Vessel Code to define a set of modified fatigue
events.

The random interaction between events option predicts a higher damage factor than applying the
defined events sequentially, unless the stress peaks from different events are marginally different. In
such cases, it is recommended to run two fatigue studies; one study with no interaction between events
and the other study with random interaction. The results can reveal that one option gives higher damage
at some locations while the other option gives higher damage at other locations.

Random Interaction between Multiple Fatigue Events

The Simulation application mixes peak stresses from different events to evaluate alternating stresses.

Suppose you specified three fatigue events that reference studies A, B, and C using scale factors Fa, Fb,
and Fc. The software calculates the alternating stresses and damage factors as follows:

For the three reference studies, the software computes the state of stress at each node scaled by the
associated factors: Sa * Fa, Sb* Fb, Sc*Fc, where Sa, Sb, and Sc refer to the stress component values [SX,
SY, SZ, TXY, TXZ, TYZ] at a node for studies A, B, and C, respectively.
For all possible pairs of load combinations, the software subtracts the six stress components of one
load case from the corresponding components of the second load case to yield the component stress
range. For n number of loadings, the possible load combinations are (n * (n -1) / 2).
For each component stress range, the software calculates the alternating stress as one-half of the
selected quantity (stress intensity, von Mises, or maximum absolute principal). The software creates a
list of the alternating stresses with the corresponding loading pairs for all possible combinations in
decreasing order.
Based on the selected fatigue curve (S-N curve), the software checks the alternating stress list from
the highest value to the lowest value.The software evaluates the partial damage factor Di for the ith
 alternating stress in that list by evaluating the cycle ratio ni / Ni (ni is the lower number of cycles
remaining from either events; Ni is the allowable number of cycles interpolated from the design
fatigue S-N curve.
After evaluating the partial damage factor, Di, the software updates the alternating stress list by
reducing the number of cycles of both events by ni. Consequently, one of the two events will be
eliminated (or both if they have the same number of cycles) and the other event will have ni cycles less
in the later calculations. Elimination of an event results in elimination of the corresponding loading.
Once a loading is eliminated, the corresponding alternating stress (formed by combining that loading
with other loadings) is also eliminated from the list.
After updating the list, the software checks the next alternating stress in the list and evaluates the
corresponding partial damage factor, adds that to the cumulative one, and updates the list. This
procedure is repeated for the next alternating stress in the list and continues until all stress values are
considered.

Example of Random Interaction for Constant Amplitude

Fatigue Events

When you select Random interaction, the software mixes peak stresses from different events to evaluate
the alternating stress.

Different loading events can interact in such a way that the maximum positive peak stress from one
event combined with the minimum peak stress from another event produces a larger alternating stress
than either one of the fatigue events.

The Random interaction option predicts a higher fatigue damage factor than applying the different
fatigue events sequentially (No Interaction). The Random interactionmethod is based on the ASME
Boiler and Pressure Vessel Code.

For example, consider these three events:

Event 1 Event 2 Event 3

Number of cycles 80,000 230,000 120,000

Min Stress 0 -300 MPa 0

Max Stress 500 MPa 0 200 Mpa

If Random interaction is considered, the sequence of events that results in the largest stress variation is
when one cycle of Event 2 proceeds each cycle of Event 1. In this case the stress fluctuates from 500 MPa
(max stress of Event 1) to -300 MPa (min stress of Event 2), resulting in a 800 MPa stress variation
(alternating stress is 400 MPa and average stress is 100 MPa).

Since there are only 80,000 cycles of Event 1, this sequence of events can happen only 80,000 times. After
the first sequence of events, there are only 150,000 (= 230,000 – 80,000) cycles remaining of Event 2.

For the next event sequence, let’s assume that one cycle of Event 3 proceeds each of the remaining cycles
of Event 2, resulting in a stress variation of 500 MPa (alternating stress of 250 MPa and an average stress
of -50 MPa).

Since there are only 120,000 cycles of Event 3, the second sequence of events can happen 120,000 times.

Finally, 30,000 cycles of Event 2 are left. This corresponds to an alternating stress of 150 MPa, with an
average stress of -150 MPa.

Random Interaction

Event 1 followed by 80,000 cycles of a 400 MPa alternating stress with an average stress of 100
Event 2 MPa

Event 2 followed by 120,000 cycles of a 250 MPa alternating stress with an average stress of -50
Event 3 MPa

Event 2 30,000 cycles of a 150 MPa alternating stress with an average stress of -150
MPa

No Interaction

Event 1 80,000 cycles of a 250 MPa alternating stress with an average stress of 250
MPa

Event 2 230,000 cycles of a 150 MPa alternating stress with an average stress of -150
MPa

Event 3 120,000 cycles of a 100 MPa alternating stress with an average stress of 100
MPa
 For studies with fatigue events referencing multiple studies, the program calculates peak stresses
based on the Random Interaction option even if you select the No interaction option.
The ASME Boiler and Pressure Vessel code recommends using theRandom Interaction option. It is
generally more conservative (predicts higher damage) than the No interaction option.

Rainflow Cycle Counting Method

The Rainflow cycle counting method extracts the composition of a variable amplitude load history. The
software implements the method as follows:

1. Extract peaks and troughs from the load history.

2. Make the amplitudes of the first and last data points the same by appending a data point if
necessary.
3. Detect the highest peak and reorder the data such that the highest peak becomes the first and last
points.
4. Start counting the peaks as follows:
1. Consider the first four peaks and troughs ( 1, 2, 3, and 4). A Rainflow cycle is counted if the second
segment is vertically shorter than the first and the third segments (i.e. b is smaller than a and c).

2. If a cycle is counted, the program starts from the beginning of the record ignoring peaks that have
already been counted. If no peak is counted, the program checks the next group of peaks (peaks
2, 3, 4, and 5) and the process continues. At the end, each peak and each trough corresponds to a
Rainflow cycle.
3. Ignore and load cycles that are below the percentage specified in the properties of the study.
4. Divide the alternating and mean stress ranges into the number of bins specified in the properties
of the study. You can view the results by viewing the Rainflow matrix chart.

Application of the Rainflow Cycle Counting Method

 Fast Counting Fast counting is used when the fatigue study
refers to one static study and has only one
variable-amplitude event. In this case, the
program extracts bins directly from the original
record. It then evaluates the damage resulting
from each bin at each node and calculates the
accumulative damage.

Full Analysis When multiple variable-amplitude events are

used, the program calculates the stresses at each
point in time for each variable-amplitude record
at every node. At each node, the program
combines the stresses and extracts the Rainflow
bins that are then used to evaluate the
damage.Full analysis is also used when a variable
amplitude record is associated with more than
one study with the different shifts or intervals.

Fatigue Plots

After you perform a fatigue analysis, you can plot life, damage and factor of safety plots for the model.

Suppose you run a static analysis and define a fatigue study with the static analysis being the only event
that occurs N times. Consider the S-N curve for the material as shown:
The program, based on the loading ratio, determines a corrected alternating stress from the static study’s
stress value for each node.

In the graph above, the green dot represents the alternating stress (Y coordinate) and number of cycles
for which the event occurs (X coordinate) for one node. One out of three possible outcomes can occur for
each node:

The dot lies above the curve. Fatigue failure is predicted at that location.
The dot lies below the curve. Fatigue failure does not occur at that location.
The dot lies outside the range of S-N curve. The highest corrected alternating stress in the model must
be within the stress range of the S-N curve. Also, the number of cycles (N) should be within the cycle
range of the S-N curve. Otherwise, instead of an intersection point, the program uses the S-N curve’s
end point.

To simplify the discussion, we did not consider the scenarios where multiple S-N curves for a material
and several events are defined.
This table describes Life, Damage, and Factor of Safety.

Fatigue Plots Description Relation Notes

Life The number of cycles Life = N – ΔN Life plot is available

that causes failure at a only when you
model location. In the define a single
graph it is the event.
intersection between Life value depends
the horizontal line for σ only on the stress
and the S-N curve. value at a location
and the S-N curve. It
does not depend on
the number of
fatigue cycles.
If the corrected
alternating stress in
the model falls
below the stress
level of the last
point of the S-N
Fatigue Plots Description Relation Notes

curve, the program

takes the number of
cycles defined for
the last point of S-N
curve, unless you
define and select
the Infinite Life
option in the
fatigue study’s
Properties, in which
case the Infinite Life
will be taken to
calculate the
Damage.
If the event is
Variable Amplitude
ofConstant
Amplitude), then
the Life results
given by the fatigue
analysis are in terms
of blocks instead of
cycles, where blocks
are defined as the
total load history
(including the
number of repeats
of the event in the
curve) specified by
the user.
 Fatigue Plots Description Relation Notes

Damage The percentage Damage = N/(N – ΔN) A value of 1

cumulative damage indicates that the
factor or the defined fatigue
percentage life events consume
consumed. 100% of the model
life at that location.

Factor of Safety The ratio of the stress FOS = (σ-Δσ)/σ The FOS plot is
value that causes available only when
fatigue failure over the a single event is
stress σ. defined in the
fatigue study.
A factor of safety of
2.0 at a location
predicts failure at
that location when
applied loads are
multiplied by 2.0.

Fatigue Result Options PropertyManager

The Result Options PropertyManager allows you to set options for the results of fatigue studies.

Fatigue Calculations

Requests damage calculations at all nodes or boundary nodes.

Whole model Calculates damage at all

locations (nodes) of the model.
In an assembly, cracks can occur
 inside the model at the
interface of two parts with
different materials. In most
other cases, cracks occur at the
model boundary.

Surface only Calculates damage at boundary

nodes only. Using this option
saves time since less
calculations are needed. The
savings are substantial for large
problems with multiple variable
amplitude fatigue loading.

Matrix Chart Locations

Sets the locations (vertices and reference points) at which you can plot the Rainflow matrix chart.

Fatigue Check Plot

Available in SolidWorks Simulation Professional and SolidWorks Simulation Premium.

Contents

Defining a Fatigue Check Plot

The Fatigue Check Plot alerts you if certain regions of your model are likely to fail due to repeated loading
and unloading over infinite time. If regions of your model are shown in red, you should set up aFatigue
study.

1. Set up a Static study with the appropriate material, contact conditions, loads and fixtures.
Allowable mesh types are: solid, shell, and mixed mesh with surface and solid bodies.
 2. After you run the study, in the Simulation study tree, right-click Results , and selectDefine Fatigue
Check Plot.
3. In the PropertyManager:
1. Under Bodies to Check, select one or all bodies.
2. Under Modifying Factors, select the Loading type.
3. Type the reduction factors for the fatigue strength of the selected bodies, or select Specify to set a
cumulative reduction factor.
In the graphics area, regions of the model that are safe from fatigue failure are blue, and regions that
are likely to fail due to fatigue are red.

You can also modify the fatigue strength and rerun the fatigue check plot module. UnderMaterial,
type a scale factor between 1 to 5 to increase it, or a safety factor between 1 to 5 to reduce it. Click in
the graphics area to update the fatigue check plot.

Fatigue Check Plot PropertyManager

The Fatigue Check Plot alerts you if certain regions of your model are likely to fail due to repeated
loading and unloading over infinite time. The plot is based on a single constant-amplitude fatigue
event with a fully-reversible or zero-based loading.

The Fatigue Check Plot alerts you if certain regions of your model are likely to fail due to repeated loading
and unloading over infinite time. The plot is based on a single constant-amplitude fatigue event with a
fully-reversible or zero-based loading.

To display this PropertyManager, run a static study. Right-click Results and select Define Fatigue Check
Plot. You need a Simulation Professional or Simulation Premium license to see this option.

The Fatigue Check plot is not available for composite shells or beams.

Bodies to Check

Select all bodies Enables selection of all bodies in your model.

Select body Selects the body to include in the Fatigue Check Plot.

Modifying Factors
Apply the reduction factors to the fatigue strength of the selected bodies. Once the reduction factors are
determined, the fatigue strength, FS(component), of the selected components in their working condition is
evaluated as:

FS(component) = FS(material) x Surface Finish Factor x Loading Factor x Size Factor

The material fatigue strength, FS(material) , equals half the material’s tensile strength.

Loading Applies zero-based fatigue loading to determine the mean and alternating
type stresses.Mean stress = Alternating stress = ½ * max [P1 or (P1-P3)/2)]

Applies fully-reversed fatigue loading to determine the mean and alternating

stresses.Mean stress = 0Alternating stress = max [P1 or (P1-P3)/2]P1,P2, P3are
the first, second, and third principal stresses, respectively.

Calculate Specifies the fatigue strength reduction factors.

Surface Specifies the correction surface finish factor. A surface finish correction allows
Finish the estimate of the fatigue strength of the part in its working condition. Select
Factor an appropriate surface finish type from the list or selectOther to enter a user-
defined value. The range is from 0.1 to 1.

Loading Specifies the correction loading factor. Fatigue limits are usually determined
Factor from test specimens under bending. A specimen loaded in tension has a lower
fatigue limit. Select a loading type from the list, or select Other to enter a user-
defined value. The range is from 0.1 to 1.

Size Factor Specifies the correction sizing factor. Based on experimental results, larger
parts have lower fatigue limits than smaller parts. The range is from 0.1 to 1.

Specify Sets the fatigue strength cumulative reduction factor which is equal to:Surface
Finish Factor x Loading Factor x Size FactorThe range is from 0.001 to 1.

Material

The material description and fatigue strength are shown when you select a single body. The fatigue check
plot calculations are performed, and you are notified if your model is susceptible to fatigue failure.
A green icon indicates that the model is safe, and will not fail under repeated cycles of loading. All
selected bodies appear blue in the graphics area.

A red icon alerts you that parts of your model could fail due to cycling loading. The regions of your model
that are susceptible to fatigue are shown in red. Run a Fatigue study to access the safety of your design in
more details.

Scale all fatigue strength Multiplies the fatigue strength of the selected
components by the given factor. The range is from
1 to 100.

Minimum safety factor Divides the fatigue strength of the selected

components by the given safety factor. The range
is from 1 to 10.

The modified fatigue strength of the component is:

Modified fatigue strength = FS(component) * Scale factor / Safety factor

Type a scale factor or safety factor larger than 1 and click in the graphics area. The fatigue check plot is
calculated and the color of the the selected components is updated in the graphics area.

Fatigue Check Plot Calculations

The blue and red regions of the fatigue check plot are determined from the diagram below. For each
node, the program calculates the alternating and mean stresses based on the defined fatigue event
type.

The blue and red regions of the fatigue check plot are determined from the diagram below. For each
node, the program calculates the alternating and mean stresses based on the defined fatigue event type.
FS(m) = Modified material fatigue strength, Sy = Material yield stress, St = Material tensile strength

For a zero-based loading fatigue event , all points are located on the 450 axis with

coordinates:mean stress = alternating stress = ½ * max [P1 or (P1-P3)/2)]where P1, P2, P3 are the first,
second, and third principal stresses, respectively.Regions of the model with corresponding points in
the green region of the diagram are blue in the fatigue check plot, and are safe from fatigue loading.
Regions of the model with points outside the green region are red in the fatigue check plot, and are
susceptible to failure due to fatigue.
For a fully-reversed loading fatigue event , all points are located on the vertical axis (mean stress

=0) with alternating stress = max [P1 or (P1-P3)/2)].Regions of the model with alternating stress
smaller than the modified material fatigue strength FS(M) are blue in the fatigue check plot, and are
safe from fatigue loading. Regions of the model with alternating stress larger than FS(M) are red in the
fatigue check plot, and are susceptible to failure due to fatigue.

FiSiBLE STaTE / Blog de WordPress.com.