Agenda

Keynote-Vortrag: Hybrid System Simulation: New Trends and Methods in Vehicle Engineering’

Authored & Presented By
Michael Burger (Fraunhofer ITWM)

Sponsor presentation: FATIQ: A Complete Solution for Fatigue Life Prediction

Authored & Presented By
George Korbetis (BETA CAE Systems)

Fatigue Strength Assessment of Fiber-Reinforced Plastic Components with Standard Material Data

Presented By
Marcus Stojek (PART Engineering)

Authored By
Marcus Stojek (PART Engineering)
V. Mortazavian (Ascend Performance Materials)

In one approach, a fatigue assessment is presented based on an isotropic simulation and the Oberbach method. Generic Wöhler curves are generated based on short-term tensile tests and local utilization ratios are calculated. In an additional step, a suggestion for an anisotropic procedure based on these generic SN curves is discussed. This includes an anisotropic material model for the stress calculation and the components stiffness.

Durability And Damage Tolerance (DADT) of AM Components

Presented By
Ramesh Chandwani (Zentech International)

Authored By
Ramesh Chandwani (Zentech International)
Chris Timbrell (Zentech International)

Keynote presentation: Structural Integrity from the Past to the Future

Authored & Presented By
Michel Guillaume (ZHAW School of Engineering IMPE)

- Loads (Aerodynamik Simulationen) - Strukturanalyse (Coarse und Detailed FE Analyse) - Fatigue Analyse (Spektrum, Materialien, Crack Growth Berechnungen)

Crack Propagation Modelling for Fatigue Analysis

Authored & Presented By
Filip Van den Abeele (Subseawolf)

Integration of System Simulations for Simple and Meaningful Fatigue Strength Testing of Substructures

Authored & Presented By
Volker Landersheim (Fraunhofer LBF)

Increasing time and cost pressure in product development and growing complexity due to system integration pose major challenges for fatigue strength analyses. Meaningful strength tests are often only possible in the context of the overall system, which leads to costly delays in the development process. Hybrid testing methods offer a solution by enabling earlier testing of substructures with less hardware. Only the relevant parts are used as Device under Test, while the behaviour of the surrounding structure is described by numerical models and simulated in the test by active or passive test bench components. This enables an efficient combination of numerical and experimental strength assessment. Such approaches also facilitate the repetition of tests for variant analyses. The presentation explains the possibilities of hybrid test setups using various project examples. German version: Steigender Zeit- und Kostendruck in der Produktentwicklung sowie zunehmende Komplexität durch Systemintegration stellen große Herausforderungen an die Betriebsfestigkeitsuntersuchungen. Aussagekräftige Festigkeitsuntersuchungen sind oft nur im Kontext des Gesamtsystems möglich, was zu kostspieligen Verzögerungen im Entwicklungsprozess führt. Hybride Prüfmethoden bieten eine Lösung, indem sie eine frühere Prüfung von Teilstrukturen mit weniger Hardware ermöglichen. Dabei werden nur die relevanten Teile als Prüfling verwendet, während das Verhalten der umgebenden Struktur durch numerische Modelle beschrieben und im Versuch durch aktive oder passive Prüfstandskomponenten nachgebildet wird. Dies ermöglicht eine effiziente Kombination von numerischer und experimenteller Festigkeitsbewertung. Solche Ansätze erleichtern auch die Wiederholung von Versuchen für Variantenuntersuchungen. Der Vortrag erläutert die Möglichkeiten hybrider Versuchsaufbauten anhand verschiedener Projektbeispiele.

Creating Surrogate (Simplified) Loads from Multiple Vibration Environments

Presented By
Neil Bishop (Hexagon)

Authored By
Neil Bishop (Hexagon)
Philippe Leisten (Purem GmbH)

A common challenge in durability analysis is to reduce measured (multi event, multi component) vibration data samples into a single surrogate load specification. This is usually done so that new design proposals can be evaluated either in a test situation or a virtual analysis. Historically enveloping has been used for this task. But the downside of enveloping is that the test specification tends to be very conservative. Recently a new procedure has been developed to generate more realistic specifications. This paper will present the required steps and underlying methodology.

Keynote-Vortrag: Fatigue Strength in Hydrogen Applications – Current Applications and Trends

Authored & Presented By
Dirk Rensink (Segula Engineering)

Fatigue Design Simulation of Mechanical Equipment Including Seven Case Studies

Authored & Presented By
Rob Widders (Consultant)

This presentation outlines the recommended engineering fatigue design simulation methods for mechanical equipment. Outlined in each step are the actions to be taken, and the standards and reference documents to be followed. This ensures that all defined steps are followed and recorded to deliver a product to address design for fatigue loadings. 11 case studies are included. The presentation details the geometrical form of the equipment, particularly at joints and transitions, which are needed to suitably accept the loading conditions, by providing good structural continuity and load paths in a holistic design manner. This presentation includes general fatigue design issues and 11 case studies the author has been involved in as principal engineering consultant, summarising what the design shortcomings were, where the fatigue issues occurred, and what the design rectification solutions were. It is trusted that the text will be of use to undergraduate, graduate as well as more senior engineers in bringing good fatigue design practices to the overall design and manufacturing processes. The presentation aims to achieve a suitable engineering practice based understanding of the nature of fatigue loadings, how and why they are usually very damaging to mechanical equipment and plant subjected to them, and the design and simulation skills and techniques needed to ensure such equipment and plant can withstand these loadings over a suitably long design life. The presentation will not be written from a metallurgy or materials science basis – rather a practical engineering design and simulation basis.

Sponsor presentation: Engineering by Magna Engineering Center Steyr

Authored & Presented By
Axel Werkhausen (Magna Powertrain Engineering Center Steyr)

Fatigue Simulation Software from Engineers for Engineers

Authored & Presented By
Axel Werkhausen (Magna Powertrain Engineering Center Steyr)

FEMFAT is developed in Engineering Center Steyr- a company, meanwhile belonging to MAGNA and so has first class reputation all over the world in automotive engineering and excellence. The software started with simple routines and coding on 6 different hardware platforms and operating systems to satisfy the customers needs down in 1986. Over the years, automotive industry is no longer the solely customer for fatigue analyses in FEMFAT. The spread of users also increases the requirements in materials, interfaces, simulated production processes and in some ways also the fulfillment of regulations like the Germanischer Loyd for wind energy gearboxes. FEMFAT combines the positive ideas for fatigue analyses from the different mechanical engineering tasks and offers the simulation engineer a wide variation of not only useful, but comfortable to use simulation tool. The presentation will showcase the process of how to improve the engineering skills from a simple fatigue analysis of a specimen to correlate the material data of a hardened shaft to the final use case when this shaft is part of the drive shaft joint. Such drive shaft joint has to withstand the loading from different inclination between driveshaft and differential, but any combination of different torque in reasonable time and with today’s workstations to make it affordable to every engineer in this business. The tool, that enables the multitude of load cases in reasonable time once has been developed for the fatigue simulation of hyper elastic natural rubber in an engine mount. The engineering skills of about 100 MAGNA simulation engineers and thousands of simulation engineers at the FEMFAT customs and universities enlarge the capability of engineering software packages by challenging the software and requesting new features to be implemented. That`s part of our plan for development and benefits the FEMFAT-community.

Fatigue Life Investigation as a Part of a Complete Design Optimization Process on Welded Structures

Presented By
George Korbetis (BETA CAE Systems)

Authored By
George Korbetis (BETA CAE Systems)
Ioannis Karypidis
Christos Tegos /BETA CAE Systems)

Product design in the automotive industry is becoming increasingly demanding as new products should reach high performance standards in very short development cycles. Engineering simulation, using FEA, comes to assist in most product development stages to substitute costly experiments for new designs while speeding up the overall processes. In this direction, optimization procedures are increasingly employed during the design. Apart from FEA, fatigue analysis is a mandatory process which assures product integrity by accurately predicting products’ life. Using fatigue analysis, the engineer is able to construct stronger yet lighter structures while avoiding over-design. Special attention should be paid to welded structures since welds often are the weakest part concerning the fatigue life. Fatigue analysis is often incorporated into the product design workflow through an optimization process that fine-tunes structures’ efficiency. In this case study, a sub-frame of a car is subjected to a cyclic load. Several design variables are defined directly to the assembly’s FE model to control its shape. The fatigue analysis as a part of an optimization loop analyzes the model and locates critical areas for improvement.

Computerized Assessment of Welds based on Finite-Element Analyses

Authored & Presented By
Peter Reimers (Iwis)

To successfully evaluate welds in structures subjected to exceptional or operational loads based on Finite Element Analyses, several conditions must be met according to the relevant standards or guidelines. While these conditions may vary in their approach, they generally share the requirement that stresses in the local weld coordinate system must be used, and that various load cases need to be considered. In order to reduce FEA modelling costs, welds in the construction are typically not explicitly represented with elements. Therefore, to perform an assessment in compliance with standards or guidelines, the engineer must not only transform the stresses calculated in the interconnected parts into the local weld coordinate system but also consider stresses in welds that are absent from the model. Additionally, a couple of necessary quantities must be computed to apply the required conditions according to the standards. WeldFEM assists engineers in this weld assessment process based on FEA calculations. This tool automatically identifies weld connections in an existing FE model, performs the required stress transformations for all elements near the weld seams, and calculates the relevant quantities for the assessment. An optimization feature helps to reduce weld seam cross sections to the minimal necessary size. The resulting utilization factors are prepared for graphical display in the FEA post-processing system and summarized in MS Excel tables for report compilation. Currently, WeldFEM supports weld assessments according to DVS 1612 and DVS 1608, DIN EN 13001, and Eurocode 3. An example will be given to demonstrate the software’s capabilities in supporting weld assessments.

Farewell

Presented By
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Authored By
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Albert Oswald (NAFEMS)
Werner Moretti (me engineering) and Alfred Svobodnik (Mvoid Group)
both members of the NAFEMS DACH Steering Committee