Creep and Creep-Fatigue Interactions: Finite Element Analysis of Time and Temperature Dependent Damage
FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization
In Thermo-Mechanical Fatigue Analysis, we use special solvers for high temperature fatigue and creep by using stress and temperature results from finite element simulations. Mechanical loads that vary at a different rate to the temperature variations can also be combined. Applications include components that are both mechanically and thermally loaded such as vehicle exhaust systems and manifolds. Finite Element analysis is used for stress analysis, but this does not answer the most important questions: How long will the component last in service? What design changes are needed to provide optimum durability? How does elevated temperature service reduce durability? What is the cause of failure: creep, fatigue, or creep-fatigue interaction?
With Combination of advanced FEA and Fatigue Analysis tools, we can solve complicated problem in power plant components, power station boilers, gas turbine blades and steam turbine components in high temperature field. Also this simulation is very necessary in powertrain industry (automotive exhaust components and turbocharger impellers) where creep and creep fatigue interaction is prevalent. We can Calculate this parameters based on clients needs:
- Where fatigue cracks will occur
- When fatigue cracks will occur
- How creep mechanisms will influence fatigue life
- The factors of safety on working stresses – for rapid optimization
- The endurance of components in high temperature environments where fatigue damage mechanisms and creep damage mechanisms interact to significantly reduce component life
Based on what we want to Design and Analysis, Stress, Strain or temperature from finite element (FE) software such as ANSYS, ABAQUS, NASTRAN, LS-Dyna, MSC Marc etc used. This FEA (Finite Element Analysis) must contain correspond simulation step detail based on what we want to do in Fatigue Simulation. Enteknograte engineers use different methodology for each specific industrial and research fields and multiphysics. MSC CAEFatigue, Ansys Ncode, Simulia FE-Safe and FEMFAT are our fatigue analysis tools.
considering Creep-Fatigue interaction in high temperature simulations identifies whether fatigue and/or creep are the dominant damaging mechanisms, thus allowing re-design to focus on the relevant damage mechanisms and significantly reduce pre-service component testing.
Damage calculation
- Thermo-mechanical fatigue damage, creep damage through Ductility Exhaustion, and fatigue-creep interaction
- Thermo-mechanical fatigue damage and fatigue-creep damage interaction based on Strain Range Partitioning
- Inelastic Strain Range Partitioning of the strain cycle and computation of plastic-plastic (PP), creep-plastic (CP), plastic-creep (PC), and creep-creep (CC) damage
- Damage for each individual cycle, including damage for uncompleted cycles
- Advanced treatment of multiaxial stresses
Durability and Fatigue Application highlights in different industry
- Fatigue Simulation in Aerospace: Wings, panels, engine blades, rivets, bondings, valves, nacelles, interior component, etc.
- Durability and Fatigue in Automotive: Chassis, rivets, bolts, wheels, connecting rods, full body systems, door, seat, dashboard, interior component, drivetrain component, underhood, oil cooler bracket, front-end carrier,Fatigue behavior of vehicle-mounted medical equipment as it interacts with the suspension dynamics of the vehicle and the road load, etc.
- Fatigue Application in Biomedical: Prosthesis, Fatigue properties of medical implants, etc.
- Durability and Fatigue in Energy sector: Pipes, vessel, valves, fan blade, pump body, Effects of the complex conditions seen in wind turbines such as vibration, the effects of rotating components and different wind states, etc.
- Fatigue Simulation in Electronics: Connectors, clips, electronic racks and housing assemblies,etc.
- Fatigue Simulation in Marine and offshore: Ship hulls and staructures fatigue analysis of welded joints using FEA models, etc.
Creep and Creep-Fatigue Interactions
considering Creep-Fatigue interaction in high temperature simulations identifies whether fatigue and/or creep are the dominant damaging mechanisms, thus allowing re-design to focus on the relevant damage mechanisms and significantly reduce pre-service component testing.
Read more... Vibration Fatigue Finite Element Simulation: Time & Frequency Domain
Structural vibration can be a source for many product related problems; it can cause fatigue and durability problems as well as adverse reactions to the user or bystanders in the form of undesirable vibrations that can be felt or heard. As well, undesired structural vibrations can prevent products from operating as required and potentially becoming a safety concern. The Vibration Fatigue simulation predict fatigue in the frequency domain and it is more realistic and efficient than time-domain analysis for many applications with random loading such as wind and wave loads.
Read more... Fatigue Analysis of Welded Structures Using the Finite Element Method
Enteknograte use advanced Numerical simulation software and methods to simulate the welding behavior in real service load condition and estimate its Durability and Fatigue Life with Ansys Ncode, Simulia FE-Safe, MSC CAEFatigue and FEMFAT. The Seam Weld and Spot Weld fatigue simulation enables the fatigue analysis of joints including different type of welding such as fillet, overlap, spot welds in thin sheets and laser welded joints.
Read more... Finite Element Analysis of Durability and Fatigue Life
Vibration Fatigue, Creep, Welded Structures Fatigue, Elastomer and Composite Fatigue with Ansys Ncode, Simulia FE-Safe, MSC CAEFatigue, FEMFAT
Durability often dominates development agendas, and empirical evaluation is by its nature time-consuming and costly. Simulation provides a strategic approach to managing risk and cost by enabling design concepts or design changes to be studied before investment in physical evaluation. The industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life and FEMFAT used to calculate fatigue life of multiaxial, welds, short-fibre composite, vibration, crack growth, thermo-mechanical fatigue.
Read more... Elastomer Materials Fatigue Finite Element Analysis
Developers of rubber materials, components and systems increasingly rely on simulation as a routine means to address design issues. For metallic components, solutions for fatigue analysis from FEA have existed commercially for many years and have become an essential part of maturing and qualifying design concepts in many industrial sectors. Using modern multiaxial strain based fatigue methods enable us to simulate the fatigue analysis of elastomer materials and Rubber.
Read more... Composites Fatigue Finite Element Simulation
The structural durability of a component is one of the most expensive attributes to test, thus one of the most appealing for CAE. Fatigue modeling of chopped and continuous fiber polymer composites is challenging due to their anisotropic, heterogeneous and viscous material properties as well as their process-dependent microstructure. For simulation of high cycle fatigue (HCF) of fiber reinforced composites we use FEA tools Like VirtualLab Durability, nCode DesignLife , MSC CAEFatigue and FE-SAFE.
Read more... Additive Manufacturing and 3D Printing
FEA Based Design and Optimization with Simufact, Abaqus, ANSYS and MSC Apex for powder bed fusion (PBF), directed energy deposition (DED) and binder jetting processes
With additive manufacturing, the design is not constrained by traditional manufacturing requirements and specific number of design parameters. Nonparametric optimization with new technologies such as Artificial Intelligence in coupled with Finite Element method, can be used to produce functional designs with the least amount of material. Additive manufacturing simulations are key in assessing a finished part’s quality. Here at Eneteknograte, dependent of the problem detail, we use advanced tools such as MSC Apex Generative Design, Simufact Additive, Digimat, Abaqus and Ansys.
Read more... Thermal Stress and Fatigue Simulation: Coupled CFD and Finite Element Approach
Enteknograte’s Engineering Team provides a comprehensive Steady-State and Transient CFD Thermal Analysis & Design services using MSC Cradle, Siemens Star-ccm+, OpenFoam and Ansys Fluent Flow Simulation. CFD Thermal Analysis extends the capability of FEA thermal analysis with MSC Nastran, Abaqus and LS-Dyna by replacing the simplistic convection boundary conditions with direct calculations of the heat transfer coefficients based on the fluid flow properties and is often referred to a conjugate heat transfer analysis.
Read more... Hydrodynamics CFD simulation, Coupled with FEA for FSI Analysis of Marine and offshore structures
Transient Resistance, Propulsion, Sea-Keeping and Maneuvering Simulation, Cavitation, Vibration and Fatigue
Hydrodynamics is a common application of CFD and a main core of Enteknograte expertise for ship, boat, yacht, marine and offshore structures simulation based design. Coupling Hydrodynamic CFD Simulation in Ansys Fluent, Siemens Star-ccm+ and MSC Cradle with structural finite element solver such as Abaqus and Ansys, enable us to Simulate most complicated industrial problem such as Cavitation, Vibration and Fatigue induced by hydrodynamics fluctuation, Transient Resistance, Propulsion, Sea-Keeping and Maneuvering Simulation, considering two way FSI (Fluid Structure Interaction) coupling technology.
Read more... Integrated Artificial Intelligence (AI) & Machine Learning - Deep Learning with CFD & FEA Simulation
Machine learning is a method of data analysis that automates analytical model building. It is a branch of Artificial Intelligence based on the idea that systems can learn from data, identify patterns and make decisions with minimal human intervention. With Artificial Intelligence (AI) applications in CAE, that is Mechanical Engineering and FEA and CFD Simulations as design tools, our CAE engineers evaluate the possible changes (and limits) coming from Machine learning, whether Deep Learning (DL), or Support vector machine (SVM) or even Genetic algorithms to specify definitive influence in some optimization problems and the solution of complex systems.
Read more... Acoustics and Vibration: FEA and CFD for AeroAcoustics, VibroAcoustics and NVH Analysis
Noise and vibration analysis is becoming increasingly important in virtually every industry. The need to reduce noise and vibration can arise because of government legislation, new lightweight constructions, use of lower cost materials, fatigue failure or increased competitive pressure. With deep knowledge in FEA, CFD and Acoustic simulation, advanced Acoustic solvers and numerical methods used by Enteknograte engineers to solve acoustics, vibro-acoustics, and aero-acoustics problems in automotive manufacturers and suppliers, aerospace companies, shipbuilding industries and consumer product manufacturers.
Read more... Heat Transfer and Thermal Analysis: Fluid-Structure Interaction with Coupled CFD and Finite Element Based Simulation
We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort. Our Finite Element (LS-Dyna, Ansys, Abaqus) and CFD simulation (Siemens Start-ccm+, Ansys Fluent , Ansys CFX and OpenFoam) for heat transfer analysis, thermal management, and virtual test process can save time and money in the design and development process, while also improving the thermal comfort and overall quality of the final product.
Read more... Multibody Dynamics
Robots Dynamics, Control Systems, Advanced Machinery, Full Vehicle MBD and NVH
Multibody dynamic analysis is important because product design frequently requires an understanding of how multiple moving parts interact with each other and their environment. From automobiles and aircraft to washing machines and assembly lines - moving parts generate loads that are often difficult to predict. Complex mechanical assemblies present design challenges that require a dynamic system-level analysis to be met. Accurate modeling can require representations of various types of components, like electronic controls systems and compliant parts and connections, as well as complicated physical phenomena like vibration, friction and noise.
Read more... Finite Element Simulation of Crash Test and Crashworthiness with LS-Dyna, Abaqus and PAM-CRASH
Crashworthiness focuses on occupant protection to reduce the number of fatal and serious injuries. This research is responsible for developing and upgrading test procedures for evaluating motor vehicle safety. Crashworthiness research encompasses new and improved vehicle design, safety countermeasures and equipment to enhance occupant safety.
Finite Element Analysis (FEA) has been the trend in virtual crash design over the last decade. The predictive capabilities of FEA allow engineers to fully understand a crash event in a virtual environment, thus limiting the number of physical tests that need to be executed and thus saving costs.
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