cae simulation & solutions maschinenbau
TRANSCRIPT
CAE Simulation & Solutions Maschinenbau Ingenieurdienstleistungen GmbHDr. Wolfgang Krach, Dr. Walter Vonach, Dr. Nikolaus Friedl
page 1www.limit-fatigue.com
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
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
?
page 4www.limit-fatigue.com
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
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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
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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
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What is LIMIT
Fatigue assessment with LIMITDeveloped for Railway IndustryComplex welded structuresRailway Standards (DVS, FKM, EC,..)Report generatorEfficient!
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Comparison of different weld typesDegree of utilization:
Results
DoU = 4,88DoU = 0,71DoU = 0,85
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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
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Weld Visualisation
Features
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Large ModelsAssessment of welded coach:
Features
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Reliable weld assessment also based on unstructured 3D meshesSensor technology
Features
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What is LIMIT
Assessments:
Static strength
Fatigue strength
Finite life strength
Codes/Guidelines:
FKM-Guideline
Eurocode 3 and 9
DVS 1612 / 1608
User defined
Crane code : DIN15018, EN13001
Stress types:
Nominal stress
Structural hot spot stress
Local stress
Embedded sensors
Interfaces:
Nastran / NX Nastran
Radioss / Optistruct
Ansys
Abaqus
Marc
SolidWorks
Features/Facts
Codes/Guidelines:
FKM-Guideline
Eurocode 3 and 9
DVS 1612 / 1608
DIN15018, EN13001
EN17149
BS7608
GB50017
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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
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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
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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
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Assessment of welds
complex structures
simple definition of welds
visual check of weld geometry
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References
LIMIT: trusted fatigue assessment
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Stress concepts
Selectable stress conceptsNominal stress
Structural Hot-Spot Stress:also for 3D Solid meshes!
Effective Notch Stress
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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
page 24www.limit-fatigue.com
What is LIMIT
Assessments:
Static strength
Fatigue strength
Finite life strength
Codes/Guidelines:
FKM-Guideline
Eurocode 3 and 9
DVS 1612 / 1608
User defined
Crane code : DIN15018, EN13001
Stress types:
Nominal stress
Structural hot spot stress
Local stress
Embedded sensors
Interfaces:
Nastran / NX Nastran
Radioss / Optistruct
Ansys
Abaqus
Marc
SolidWorks
Features/Facts
Codes/Guidelines:
FKM-Guideline
Eurocode 3 and 9
DVS 1612 / 1608
DIN15018, EN13001
EN17149
BS7608
GB50017
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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
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Codes and guidelines
FKM-Guideline Eurocode 3 and 9, GB50017
Crane codesDIN 15018 and EN13001
DVS1612, DVS1608, BS7608, EN17149
DangVan User defined fatiguedata
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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
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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
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Main ObjectiveFinding critical loads and load cycle numbersChecking all critical positionsApplying different design codes Strong focus on welds and Large structures
Motivation for LIMIT
?
page 44www.limit-fatigue.com
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
page 45www.limit-fatigue.com
Strongly mesh dependant results:
Stresses in Welded Structures
!