CAE Simulation & Solutions Maschinenbau Ingenieurdienstleistungen GmbH

CAE Simulation & SolutionsMaschinenbau Ingenieurdienstleistungen GmbHDr. Wolfgang Krach, Dr. Walter Vonach, Dr. Nikolaus Friedlwww.cae-sim-sol.comLIMIT 2017Page 1

Company Profile and HistoryWho we are:Engineering service provider Based in Vienna, Austria Company founded 2002Main fields of activities Structural mechanics Strength assessments of structures Simulation of production processes More than 700 projects conducted Computational fluid dynamics Since 2010 Flow and heat transfer projects Software development Primarily for internal use LIMIT since 2004, available forcustomers since 2010www.cae-sim-sol.comLIMIT 2017Page 2

Services, Methodology & SoftwareServicesfrom idea to designStand Alone ApplicationsCAD - IntegratedDraftCatiaSWXFinite Element AnalysisStrength assessmentsHyperworksAbaqusFlow Simulation /Energy TransferFluent /OpenFoamPatran/NastraMarcLIMITSWX / SimulationSWX / FlowSimulationMeasurments/TestsSoftware SalesTraining/Supportwww.cae-sim-sol.comFEA TopicsLIMIT 2017AllAllPage 3

The SoftwareEfficient and conforming-to-standard fatigueassessment with LIMITwww.cae-sim-sol.comLIMIT 2017Page 4

Motivation for LIMITMain ObjectiveFinding critical loads and load cycle numbersChecking all critical positionsApplying different design codes Strong focus on welds and Large structures?www.cae-sim-sol.comLIMIT 2017Page 5

LIMIT Within the Simulation ProcessGlobal iterationloop, changinggeometryDesign: 3D-CAD3D-CADFE modelPatran, Hypermesh,Abaqus/CAE, ANSYS, NXFinite Element Input.bdf, .out, .dat, .inpLIMIT-CAEDefinition of assessmentsin the GUIMidsurfaces and shellelementsFE SolverNastran, Abaqus, ANSYSFE Results.fil, .odb, .op2, .rstLIMIT-SOLVERLocal loop, e.g.changing weldqualityAnalysisLIMIT-VIEWERDegree ofutilization in weldsPost processingwww.cae-sim-sol.comLIMIT 2017Page 6

AssessmentAssessment of base material static strength / fatigue strength Very efficiently using FKM guideline, 6th editionCrank shaftEffects taken into account stress gradients normal to surface surface factors temperatureCentre pinwww.cae-sim-sol.comLIMIT 2017Page 7

AssessmentAssessment of welds with nominal or structural hot spot stressesa.) complex structuresb.) simple definition of weldsc.) visual check of weld geometryb.)c.)a.)underframe metrowww.cae-sim-sol.comLIMIT 2017Page 8

AssessmentAssessment of welds with nominal or structural hot spot stresses static and fatigue assessmentwww.cae-sim-sol.com numerous codes availableLIMIT 2017 simple post processingPage 9

The SoftwareFeatures/FactsMesh Tet10Assessments:Stress types: Static strength Nominal stress Fatigue strength Structural hot spot stress Finite life strength Local stress Embedded sensorsFlangeCodes/Guidelines:Interfaces: FKM-Guideline MSC Nastran / NX Nastran Eurocode 3 and 9 MSC Marc DVS 1612 / 1608 Radioss / Optistruct (EN 17149 planned) Ansys User defined Abaqus Crane code :DIN15018, EN13001 Catia FE (Tetras)www.cae-sim-sol.comStructural hot spot assessment SolidWorksLIMIT 2017Page 10

Advantages using LIMITAdvantages using LIMITReduction of time-to-marketReduction of risk of failure Comprehensive and accurate assessment Quality is improved, especially compared tomanual assessment Saves money due to less cases of warrantySimple to use for engineers low costs for trainingfatigue cracks in weldswww.cae-sim-sol.comLIMIT 2017Page 11

ReferencesReferences AMST-Systemtechnik GmbHAUDI, Werkzeugkonstruktion, GermanyBühler AG, SwitzerlandChina Energine International Ltd.FEMCOS-Ingenieurbüro mbH, GermanyGardner Denver Schopfheim GmbH, GermanyHydromek, TurkeyIBV-Engineering, GermanyIFF Engineering & Consulting GmbH, GermanyIstanbul Technical University, TurkeyK V Ingenieurgesellschaft mbH, GermanyLudwig Engel KG, AustriaLiebherr-Transportation Systems GmbH & Co KGwww.cae-sim-sol.com LogoMotive GmbH, GermanyMAV-START, HungaryNEWAG, PolandPESA Bydgoszcz SA, PolandPrisma Engineering, AustriaRUAG Schweiz AG, SwitzerlandStadler Valencia, SpainSTREICHER Maschinenbau GmbH & Co. KG, GermanyTUV Rheinland Rail Sciences, Inc., Nebraska, USAVossloh Locomotives, KielLIMIT 2017Page 12

FKM, Fatigue/Static StrengthStress Concepts for Welded Structureswww.cae-sim-sol.comLIMIT 2017page 13

Modelling Techniques in LIMITWeld Analysis with LIMITSingle sided fillet weld Fillet throat critical stresses in throatneeded!C.)B.)A.) Using section forces from shell modelB.) Using section forces fromA.)solid model & LIMIT sensorsC.) R1-effective notchno IMIT 2017page 14

Modelling Techniques in LIMITWeld Analysis with LIMITDouble sided fillet weldC.) Weld toes critical simpler approachA.) Shell stresses can be usedB.) Solid model & LIMIT sensorsC.) CAB-method (structural stressat transition lines)B.)A.)r (2 x a),avoids IMIT 2017page 15

Modelling Techniques in LIMITWeld Analysis with LIMITExample: Solid modeling &weld assessment with sensorswww.cae-sim-sol.comLIMIT 2017page 16

Stresses in Welded StructuresStrongly mesh dependant results:!www.cae-sim-sol.comLIMIT 2017page 17

Stresses in Welded StructuresStress concepts for welded structuresNominal stressF classic conceptNotch stress(peak stress)FStructural hot spotstress (IIW)www.cae-sim-sol.comLIMIT 2017page 18

Stress ConceptsNominal stressesStresses relating to nominal sectionPermissible stresses include:(II)(I) Stress increase due to change instiffness (I) Local notch effect throughweld root or weld toe (II)Source: EC3www.cae-sim-sol.comLIMIT 2017page 19

Stress ConceptsStructural hot spot stressAccording to IIW(International Institute of Welding)Structural Hot Spot Stress(II)(I)Stresses include structural effect (I)Permissible values include notch of weld (II)xSource:FKM Guideline 2012www.cae-sim-sol.comLIMIT 2017xpage 20

Stress conceptsEffective notch stressNotch stressAccording to RadajToe and root modeled with Radius 1mmLinear elastic analysisCalculate stress rangeFor structural steel: FAT 225 (at 2 mio. cycles)Only for detail studies usablePeak StressWelded Assemblywww.cae-sim-sol.comLIMIT 2017Page 21

Assessment Concepts, SensorsStructural Hot Spot / Nominal Stresses for Solid ElementsSensors embedded within the solid modelExtracting structural stresses for weld toesLinear extrapolation schemeaccording to IIWAveraged stress datacomparable to shell resultswww.cae-sim-sol.comSensorHot Spot StressLIMIT 2017page 22

Assessment Concepts, SensorsStructural Hot Spot Stresses for Solid ElementsGeneration of sensors with LIMIT SensorManagerwww.cae-sim-sol.comLIMIT 2017page 23

Assessment Concepts, SensorsStructural Hot Spot Stresses for Solid ElementsSensors: definition of welds in same way as for shellswww.cae-sim-sol.comLIMIT 2017page 24

Critical PointsWeld Analysis with LIMITBasic features of LIMIT Checking all critical points(red circles) Base material Weld section Toes and Rootsm www.cae-sim-sol.comn LIMIT 2017page 25

Stresses and Section ForcesAssessment Points within LIMITAre used to perform the fatigue analysisfor potential areas of crack initiationAre defined relative to shell normalP1 to P4 . Weld Section P1, P4 toe P2, P3 rootP5 and P6 . Base MaterialWeld dimensions A-Bot welded from bottom side A-Top welded from top sideRoot Position (midplane to root) D-Bot welded from bottom side D-Top welded from top sidewww.cae-sim-sol.comLIMIT 2017Page 26

Stresses and Section ForcesSingle sided fillet weld, Stresses in P3, roott sheet thicknesscontinously weldedt/2 t/2TopBottomStress lateral to weld direction at rootOnly n , m 0A weld sectione excentricityAs , P3 n / A n 6 e / A² n (1 / A 6 e / A²)P4P3snom n / As , P3 snom (1 6 e / A)eExample: A t, e t (full excentricity)s , P3 snom (1 6)www.cae-sim-sol.comm LIMIT 2017n page 27

FAT-ClassesFAT classes, one sided fillet weld:Only nominalstress, toe:Typical values:s sllts s sllt2Nominal stress,toe:t1FATll 100FAT 71 80FATt 80t2FATll 100FAT 71FATt 80aStructural stress,toe (IIW)Only nominal stress, root:FATll 100FAT 100FATt 80FATll 100FAT 36 Excentricity!FATt 80t1www.cae-sim-sol.comLIMIT 2017page 28

ResultsTypical resultsIn the following section results are compared and documented for different weld types :a.) One sided full penetration weldb.) Double sided fillet weldc.) One sided fillet welda.)www.cae-sim-sol.comb.)c.)LIMIT 2017Page 29

ResultsComparison for different geometriesDegree of Utilization (DoU)DoU 0,85www.cae-sim-sol.comDoU 0,71DoU 4,88LIMIT 2017Page 30

Apply for a free test license and experience the benefits for your projects!Please contact:Dr. Nikolaus Friedlfriedl@cae-sim-sol.at 43 1 974 89 91-12www.cae-sim-sol.comLIMIT 2017Page 31

Simulation of production processes More than 700 projects conducted . at transition lines) Sensors A.) B.) C.) Cracks Load r (2 x a), avoids singularities. www.cae -sim sol.com LIMIT 2017 page 16 Modelling Techniques in LIMIT Weld Analysis with LIMIT Example: Solid modeling & weld assessment with sensors. www.cae -sim sol.com LIMIT 2017 .