CAE Simulation & Solutions Maschinenbau

CAE Simulation & Solutions Maschinenbau Ingenieurdienstleistungen GmbHDr. Wolfgang Krach, Dr. Walter Vonach, Dr. Nikolaus Friedl

page 1www.limit-fatigue.com

Prezentator

Notatki do prezentacji

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www.limit-fatigue.com Seite 2

Who we are:Engineering service provider Based in Vienna, Austria Company founded 2003Main fields of activities Structural mechanics− Strength assessments of structures− Simulation of production processes− More than 800 projects conducted Computational fluid dynamics− Since 2010− Flow and heat transfer projects Software − Development− Sales− Training/Support

Company Profile and History

Prezentator

Notatki do prezentacji

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Seite 3www.limit-fatigue.com

Main ObjectiveFinding critical loads and load cycle numbersChecking all critical positionsApplying different design codesStrong focus on welds andLarge structures

Motivation for LIMIT

?


What is LIMITKey features

Fatigue and static assessment of FEM stress results

Identification of all critical positions in the structure with respect to fatigue or static failure

Calculation of corresponding safety values as defined in design codes (DVS, FKM, EC, EN13001,…)

Detection of critical loads and load combinations

Auto report generator


What is LIMIT

Assessments:

Static strength

Fatigue strength

Finite life strength

Codes/Guidelines:

FKM-Guideline

Eurocode 3 and 9

DVS 1612 / 1608

DIN15018, EN13001

EN17149

BS7608

GB50017

Stress types:

Nominal stress

Structural hot spot stress

Local stress

Embedded sensors

Interfaces:

Nastran / NX Nastran

Radioss / Optistruct

Ansys

Abaqus

Marc

SolidWorks

Features/Facts


Modelling Techniques in LIMITWeld Analysis with LIMIT

Example: Single sided fillet weld Fillet throat critical => stresses in throat

needed!A.) Using section forces from shell model B.) Using section forces from

solid model & LIMIT sensors C.) R1-effective notch

Sensors

A.)

B.)

C.)

Cracks

Load

no singularities


What is LIMIT

Fatigue assessment with LIMITDeveloped for Railway IndustryComplex welded structuresRailway Standards (DVS, FKM, EC,..)Report generatorEfficient!


Comparison of different weld typesDegree of utilization:

Results

DoU = 4,88DoU = 0,71DoU = 0,85


Structural hot spot stressAccording to IIW(International Institute of Welding)Stresses include structural effect (I)Permissible values include notch of weld (II)A step to mesh independency and accuracy

Stress Concepts

xx

Structural Hot Spot Stress

(II)

(I)

Source:FKM Guideline 2012


Weld Visualisation

Features


Large ModelsAssessment of welded coach:

Features


Reliable weld assessment also based on unstructured 3D meshesSensor technology

Features


What is LIMIT

Assessments:

Static strength

Fatigue strength


Codes/Guidelines:

FKM-Guideline

Eurocode 3 and 9

DVS 1612 / 1608

User defined

Crane code : DIN15018, EN13001

Stress types:

Nominal stress


Local stress

Embedded sensors

Interfaces:



Ansys

Abaqus

Marc

SolidWorks

Features/Facts

Codes/Guidelines:

FKM-Guideline

Eurocode 3 and 9

DVS 1612 / 1608

DIN15018, EN13001

EN17149

BS7608

GB50017


Effects taken into account:yieldingstress gradients normal to surfacetemperature...

Assessment of base material

Base material studiesstatic strength / fatigue strengthvery efficient using FKM guideline, 6th edition

Crank shaft

Centre pin


From stress to safety

stresses

min. safety at welds

In welded structures, critical areas with respect to strength don’t coincide with areas of increased stresses, due to

Weld type and geometryLocal loading condition

LIMIT allows a highly efficient consideration of these effects


Stress evaluation points

n⊥m⊥

Weld Analysis with LIMITBasic features of LIMIT:Checking all critical points

(red circles)−Base material−Weld section−Toes and Roots


Assessment of welds

complex structures

simple definition of welds

visual check of weld geometry


References

LIMIT: trusted fatigue assessment


Stress concepts

Selectable stress conceptsNominal stress

Structural Hot-Spot Stress:also for 3D Solid meshes!

Effective Notch Stress


Load definitions

Superposition of basic load casesRainflow countNon-proportional loadingFinite life and infinite lifeScaled normal stress for base materialCritical section plane approaches for all codesIIW recommendation for non-proportional loading of weldings


What is LIMIT

Assessments:

Static strength

Fatigue strength


Codes/Guidelines:

FKM-Guideline

Eurocode 3 and 9

DVS 1612 / 1608

User defined

Crane code : DIN15018, EN13001

Stress types:

Nominal stress


Local stress

Embedded sensors

Interfaces:



Ansys

Abaqus

Marc

SolidWorks

Features/Facts

Codes/Guidelines:

FKM-Guideline

Eurocode 3 and 9

DVS 1612 / 1608

DIN15018, EN13001

EN17149

BS7608

GB50017

Seite 25www.limit-fatigue.com

LIMIT Within the Simulation Process

FE modelPatran, Hypermesh,

Abaqus/CAE, ANSYS, NX

Design: 3D-CAD

Finite Element Input.bdf, .out, .dat, .inp

FE Results.fil, .odb, .op2, .rst

LIMIT-SOLVERAnalysis

LIMIT-VIEWERPost processing

FE SolverNastran, Abaqus, ANSYS

Midsurfaces and shell elements

3D-CAD

Degree of utilization in welds

LIMIT-CAEDefinition of assessments

in the GUI

Global iteration loop, changing

geometry

Local loop, e.g. changing weld quality


Codes and guidelines

FKM-Guideline Eurocode 3 and 9, GB50017

Crane codesDIN 15018 and EN13001

DVS1612, DVS1608, BS7608, EN17149

DangVan User defined fatiguedata


FKM training courseIntroduction to Strength Assessment according to the FKM Guideline using the Software LIMIT

Two-day course to provide participants with an overview of the FKM guidelineThis course is designed for stress engineers, who are familiar with the method of Finite Element AnalysisIntroduction into different stress concepts such as nominal, structural hot spot and local notch stressExamples for welded and non-welded components for static and fatigue strength assessmentOrganization / Contact see www.cae-sim-sol.com


ReferencesReferences

ABB, Polen AKG, Germany AMST-Systemtechnik GmbH AUDI, Werkzeugkonstruktion, Germany Bühler AG, Switzerland Bilfinger VAM, Austria Brogent, Taiwan CAF, Spain Celtic Engineering, USA China Energine International Ltd. CRRC, China DB Cargo, Germany FEMCOS-Ingenieurbüro mbH, Germany Gardner Denver Schopfheim GmbH,

Germany Hydromek, Turkey IBV-Engineering, Germany IFF Engineering & Consulting GmbH,

Germany Ingenieurbüro Stengel GmbH, Germany

Indusim, Germany Istanbul Technical University, Turkey IW-Maschinenbau, Germany Komes, Poland K + V Ingenieurgesellschaft mbH,

Germany Liebherr-Transportation Systems,

Austria LogoMotive GmbH, Germany Ludwig Engel KG, Austria MAV-START, Hungary Matisa, Switzerlanf NEWAG, Poland PESA Bydgoszcz SA, Poland OEBB TS, Austria Plasser & Theurer, Austria Politecnico di Milano, Italy Prisma Engineering, Austria

RUAG Schweiz AG, Switzerland Schindler, Switzerland Sedax, Switzerland Stadler Valencia, Spain RC Stengel, Germany Streicher Maschinenbau, Germany Talgo, Spain Topu, Taiwan Trelleborg, Switzerland TRSC, Taiwan TUV Rheinland Rail Sciences, USA Vossloh Locomotives, Kiel VUKV, Czech Republic Viessmann, Germany WeissQuadrat, Lichtenstein Zamperla, Italy

www.limit-fatigue.com Seite 43

Main ObjectiveFinding critical loads and load cycle numbersChecking all critical positionsApplying different design codes Strong focus on welds and Large structures

Motivation for LIMIT

?


Modelling Techniques in LIMITWeld Analysis with LIMIT

Single sided fillet weld Fillet throat critical => stresses in throat

needed!A.) Using section forces from shell model B.) Using section forces from

solid model & LIMIT sensors C.) R1-effective notch

Sensors

A.)

B.)

C.)

Cracks

Load

no singularities


Strongly mesh dependant results:

Stresses in Welded Structures

!

Documents

CAE Simulation & Solutions Maschinenbau