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Multidisciplinary Fatigue Workflows
using the Simulia Portfolio
October 2016
Mark WyattBusiness Development ExecutiveSIMULIA, Fatigue and Durability
DS SIMULIA Corp.
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SIMULIA’s Power of the Portfolio
Predict and Analyze Product Life
• Fatigue Analysis
• Durability Prediction
• Fatigue Analysis
• Durability Predictionfe-safe
Process Automation & Design Optimization
Isight• Design/Runtime Gateway
• Application Components
• Process Drivers
• Design/Runtime Gateway
• Application Components
• Process Drivers
Continued Technology Leadership & Innovation
More Physics, Open Co-Simulation
Abaqus
• Abaqus/CAE
• Abaqus/Standard
• Abaqus/Explicit
• Abaqus/CFD
• CEL, FSI, SPH, EMAG
• Abaqus/CAE
• Abaqus/Standard
• Abaqus/Explicit
• Abaqus/CFD
• CEL, FSI, SPH, EMAG
Non-parametricDesign Optimization
Tosca• Structural & Fluid Flow Optimization
• Conceptual & Detailed Design
• Topology, Sizing, Shape, Bead Optimization
• Structural & Fluid Flow Optimization
• Conceptual & Detailed Design
• Topology, Sizing, Shape, Bead Optimization
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Extended Packaging
SIMULIAExtended Package
Licensing
fe-safe
Abaqus
Tosca
(struc+fl)
Isight
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Andy and Laura� Retired couple from Bay Area,
CA;
� Love to travel to Flagstaff, AZ.
� Andy: 64, health good; hip implant
from osteo-arth. initiated in auto
accident (control arm bushing
failure) in 1975. Loves to ride his
motorcycle.
� Laura 62, health good; some
heart issues. Arterial stents
solved main issues. Loves fly
fishing.
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Bushing workflow
fe-safe/Rubber
fatigue analysisAbaqus
stress analysisAbaqus
stress analysis
Isight parametric
optimization
Tosca nonparametric
shape optimization
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Controller approach to reduce stress concentration
Shape optimization using Tosca
� Design surface: free surface
� Constraint
� Stamping constraint: two bean shaped holes
� Symmetric constraint: all design nodes
� Freeze constraint: nodes tied to the rigid bodies
� Mesh smoothing
� Objective
� Minimize damage value:
where N is number of cycles to fatigue
1
log�
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Optimization results
• Worst life in number of cycles
increase from 6833 to 13662
(~99.9%)
• Number of iterations: 12
• Cost: 2 hr 23 min with 1 CPU
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Validation fe-safe runs before and after shape optimization
Fatigue analysis of a rubber bushing
• Worst life improved from 6833 cycles to 13662 cycles (~99.9% increase)
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Bushing workflow
fe-safe/Rubber
fatigue analysisAbaqus
stress analysisAbaqus
stress analysis
Isight parametric
optimization
Tosca nonparametric
shape optimization
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Imagine
Workbench testing of 200 variants
���� Certification in 60 days
Virtual testing through SIMULATION
Each variant takes less than 5 min
Workbench testing of one variant: 12 days
���� Certification in less than 2 weeks
200 variants 200 variants
40 test machines 1 test machine
ISO 7206/4, ASTM F2996-13
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Design of Experiments to automatically generate, test, and evaluate all variants
Isight Process Automation
� Execute ISO 7206/4 virtual testing for all variants in a couple of hours
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Isight Workflow: fe-safe
Virtual Testing with Isight
� fe-safe fatigue analysis
�Run fe-safe fatigue analysis
� Uses Abaqus FEA results
� automatically executed within Isight workflow
�Life results
� Worst Life Repeats
� Factor of Strength (FOS) plots
Abaqus ParallelUp to 60%Token
usage reduction
In Isight
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Isight Workflow Execution
Virtual Testing with Isight
� Overall virtual testing takes just a couple of hours on a standard workstation
� Virtual testing with Abaqus and fe-safe takes less than 5 minutes per variant
� Fatigue life using shape optimization was increased 4.8 times
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ReliabilityAnalysis
Stress AnalysisNon-Parametric
Design Optimization
Parametric Design
Optimization
Fatigue Life
Fatigue Life
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ReliabilityAnalysis
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Reliability Analysis on Stents
� The thickness of the artery presents the
largest source of uncertainty in the
model
� Radii with +/- 2.5% variation assumed
�Outer – 1.62 mm mean and 0.02784 mm
SD
� Inner - 1.132 mm mean and 0.018 mm
SD
Inner
Radius
Outer
Radius
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Reliability Analysis on Stents Response Surface
(fe-safe)
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This workflow illustrates how SIMULIA Portfolio can help engineers
redesign motorcycle brake rotor geometry towards more reliable,
lightweight and durable design
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Process to Accelerate Innovation
Conceptual lightweight design
Topology Optimization
- Tosca Structure
Insured reliability
Durability Analysis
- fe-safe
Understand physical behavior
Structural & Thermal Analysis
- Abaqus
Exploration of design alternatives
Parametric Optimization
- Isight
Improved structural integrity
Shape Optimization
- Tosca Structure
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Results Comparison
Durability Analysis
� After shape optimization:
�More rounded shape
�Less gradient
�Life is longer
(infinite life design was achieved)
�Higher Factor of Strength (1.4)
FOS
Initial Optimized
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Jing Bi
George Ang
Gergana Dimitrova
Jiang Yao
Manoj Chinnakonda
Manuel Biedermann
Sandy Eyl
Yangwook Cho
Robert Combier
Steven Ribeiro-Ayeh
Pawel Sobczak
Jegan Chinnaraju
Michael Werner
Cheryl Liu
Joe Haemer
