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LMS Virtual.Lab Durability

LMS Virtual.Lab DurabilityDesigning for optimal durability performance

2 LMS Virtual.Lab Durability

3LMS Virtual.Lab Durability

LMS Virtual.Lab DurabilityDesigning for optimal durability performance

Transforming durability challenges into advantages

Shorter development cycles and increased quality requirements have stretched traditional test-based durability processes to the limit. Evaluating and reliably optimizing durability performance on a virtual prototype is the only valid alternative. Just a few years ago, predicting component-level fatigue life took weeks while a system-level analysis could translate into months - if possible at all. Exploring multiple options to optimize design durability was simply not feasible and the only real option was to use expensive hardware treatments late in the development cycle.

Thanks to years of customer and research institute experience, LMS Virtual.Lab Durability tightly integrates various virtual prototyping aspects including fi nite element (FE), modal analysis, multi-body simulation (MBS) and fatigue-life prediction. Users can quickly explore and optimize the structural strength and fatigue life on both component and system assembly levels in time or frequency domains. LMS Virtual.Lab Durability executes fast and accurate durability predictions. Dedicated post-processing capabilities provide engineers with immediate feedback regarding all critical durability areas, critical loads and critical events.

Undoubtedly the most challenging task for durability engineers is designing fail-safe components and systems in the most effi cient manner. System parts with insuffi cient fatigue strength may cause permanent structural damage and potentially life-threatening situations. Mistakes can cause product recalls which negatively infl uence the overall brand image. In addition to this, short design cycles, more design variants and increased usage of new lightweight materials increase the complexity of the durability engineering process.

Validate more design variants • for fatigue life within ever-shorter development cycles

Confi dently simulate durability • performance of large-and complex systems

Optimize durability • performance with lightweight and eco-friendly materials

Better understand and • improve fatigue testing

LMS International | [email protected] | www.lmsintl.com4 LMS Virtual.Lab Durability

Virtual Shaker Table

Shaker tables are a key testing facility. Already in the design phase, efficient simulation of sine sweeps, harmonic excitations and random loads helps optimize durability behavior. Specifically, LMS Virtual.Lab Vibration Fatigue is the tool to set up any virtual shaker table experiment from simple excitations to complex multi-axial scenarios.

Automotive and Ground Transportation

LMS Virtual.Lab Durability accurately traces the fatigue performance of each vital chassis component. LMS Virtual.Lab Durability efficiently predicts fatigue-life on body frames, panels, cross-members and door systems as well as on sunroofs, latches and locking systems. LMS Virtual.Lab Durability also guarantees a high degree of accuracy for specific seam weld and spot weld analyses. Advanced numerical durability predictions can be applied to specific engine and powertrain parts. Engine brackets, gear box chain heels and exhaust lines are typical examples of components that can be effectively optimized with LMS Virtual.Lab Durability.

LMS Virtual.Lab Durability Solutions for:

Aerospace

LMS Virtual.Lab Durability predicts mechanical system fatigue life for landing gear, control mechanisms, slat tracks and other critical assemblies. Local stress concentrations are identified based on all possible combinations of local load conditions to address durability problems long before prototypes are built. A wide range of methods can localize weak spots and assess fatigue life.

Industrial machinery

In industrial applications, economic efficiency and safety depend on critical parts typically subjected to large dynamic multi-axial load cases. Any metal component subjected to dynamic loading cycles can be efficiently optimized. LMS Virtual.Lab Durability is capable of accurately determining rotor base fatigue life in large wind turbines or crane parts integrated in industrial trucks.

5LMS Virtual.Lab DurabilityLMS International | [email protected] | www.lmsintl.com

An integrated process approach to durability engineering

Outstanding accuracy through in-depth investigationAssessing load effects can be challenging, particularly with multiple independent inputs that generate forces with local multi-axial stress states, LMS Virtual.Lab achieves outstanding accuracy by treating these cases based on the critical plane approach, which accounts for anisotropy caused by microscopic small cracks. Fatigue cracks below the surface can be analyzed as well.

Fatigue-life solver fit for rigid and flexible bodiesWhile components such as knuckles are never excited close to their natural frequencies, other parts such as suspension sub-frames, truck chassis, or exhaust systems are. To accurately and efficiently tackle any situation, LMS Virtual.Lab Durability supports different approaches for predicting stresses, based on quasi-static, inertial relief and modal superposition techniques.

Top analysis speed with smart data reductionWhen creating real-life industrial size models, LMS Virtual.Lab Durability intelligently and automatically reduces the amount of data via node elimination reverse path (RP) filtering and load-based filtering. There is no need to guess where the critical locations might be - all locations are found automatically. Analyzing a complex car body model with hundreds of spot and seam welds and over 350,000 elements takes just a few hours.

The LMS fatigue solvers have been maturing for almost two decades to guarantee fast and accurate results. Technology breakthroughs in intelligent filter algorithms, analysis for welded structures, application of time dependent stress gradients are just some examples of recent technological innovations. This is accompanied by usability breakthroughs, like the only real seamless integration of multi-body simulation and fatigue, state-of-the-art automation tools, and optimal post-processing tools to analyze the source of fatigue problems.

Efficient seam and spot weld assessmentsVehicle body and suspension systems can include thousands of welds. For spot welds, LMS Virtual.Lab Durability supports the Rupp/LBF approach, CDH and a special JSAE model as well as a stress-based approach using detailed modeling.

LMS Virtual.Lab Durability automates seam-weld durability assessments, eliminating the tedious task of adapting the FE mesh according to seam-weld meshing guidelines. Users simply define the manufacturing details and LMS Virtual.Lab Durability identifies local stress concentrations based on all the possible combinations of (local) load conditions. Sheet connections are automatically detected and classified according to element or predefined groups while connection types are automatically classified according to butt welds, overlap joints and T-joints.


From component-level to system-level durability predictionFull-assembly design issues are too often discovered late in the development process. To solve this, durability engineers need to optimize subsystems or systems as a whole. This is where LMS Virtual.Lab Durability steps in. It tightly integrates multibody simulations with fl exible-body analyses and fatigue-life predictions. The durability performance of any particular system part can be effectively and accurately traced. LMS Virtual.Lab’s proven solver technology and real-life modeling capabilities guarantee top-class prediction accuracy.

Accurate system load simulationLong before the actual vehicle prototype is created, LMS Virtual.Lab Durability can be used to generate system loads, starting from virtual driver sessions or road tests from a previously released vehicle. The LMS Digital Test Track approach predicts spindle loads via realistically simulated driver sessions. A virtual vehicle is equipped with virtual tires and drives over a digitized test track. For tracks and public roads that are too complex or expensive to digitize, LMS Virtual.Lab Durability offers a valid alternative. The LMS Hybrid Road approach incorporates test-based system loads from a predecessor vehicle to generate loads for the new vehicle design.

Automated durability analysisLMS Virtual.Lab Durability provides all the automation functionalities to defi ne a complete durability analysis case from scratch. Users will benefi t from the powerful LMS Virtual.Lab toolset to defi ne templates and to effi ciently automate the preparation of loads and post processing cases. Furthermore, the automation functionality provides extensive fl exibility to interact with external optimization tools.

LMS Virtual.Lab Durability

CAD MeshingMesh based

Pre-processingStandard

LoadsStress

SimulationFatigue

Simulation

Re-use CAD and CAE models from industry-standard tools.

Transfer loads from multi-body simulation to durability analysis.

Set-up and solve fatigue problems. Automation tools solve hundreds of cases and prepare the post-processing.

DurabilityPerformance


Features Benefits

...users interactively define the load case to be applied to the component.

LMS Virtual.Lab Durability runs the fatigue analysis and determines the critical regions.

Based on the analysis results, users can change their design and evaluate the impact on the fatigue resistance.

VL-DUR.24.2

Process solution that tightly integrates • FE, test and fatigue life prediction Seamless access to structural FE meshes • and stresses from all leading FEA tools Direct component-load importing • from prototype measurements or multibody simulation based on LMS and 3rd party time-data formats Industry standard fatigue-life solver • with proven accuracy and speed Dedicated durability visualization • and post-processing tools Analysis templates that capture • simulation workflow

Reduce fatigue analysis time• Quick and accurate fatigue life predictions • based on realistic loading conditionsImmediate feedback on • critical durability areasUnderstand the cause of fatigue problems• Explore multiple design options and • optimize the design for fatigue performance

Starting from a component designed in CATIA V5...

LMS Virtual.Lab Component FatigueLMS Virtual.Lab Component Fatigue is a complete solution to accurately assess the fatigue performance of individual components in one single, integrated simulation environment. By combining component loads derived from prototype measurements or multibody simulations, FE-based stress results and cyclic fatigue material parameters, LMS Virtual.Lab Component Fatigue allows engineers to predict fatigue hotspots and corresponding fatigue life, and optimize the component design for fatigue performance.

The straightforward interface offers a clear built-in workflow and set-up templates to guide users through the process. With seamless access to FE meshes and stresses, automatic Nastran and Ansys driving, and direct component load importing, users can quickly prepare fatigue analyses all within the same environment.

LMS Virtual.Lab Component Fatigue offers all the fatigue-life analysis capabilities of the popular LMS FALANCS solver, including assessment of low-cycle fatigue, high-cycle fatigue and infinite life, stress gradient correction, below-surface fatigue as well as seam and spot weld analysis.

With dedicated post-processing functionalities, engineers can quickly identify and solve fatigue life problems, and experiment with multiple design options. Parametric analyses let users identify innovative design solutions before physical prototyping.


Benefits

Features

Easy creation of multibody models for • system load prediction and cascading of system loads to component loading Automatic transfer of component loads for • detailed component durability analysis Optimize durability performance by • tuning system characteristics for optimal load input Parallel optimization of motion, • loading and fatigue Flexible body modeling and robust • multibody solver guarantee accurate component load prediction

Analyze durability performance earlier in • the design process before flexibility is lostSafe and efficient process avoids • manual load transferQuickly explore fatigue life of • multiple system-level designsAccurately predict component loads• Optimize system-level fatigue performance • by optimizing load-transfer paths

VL-DUR.25.2

The stress recovery is automatically transferred to the durability analysis.

The fatigue results can also be post-processed in the complete system.

Optimize the ride and handling behavior of the suspension; easily apply the real road profiles.

Replace the knuckle by a flexible representation with one mouse click.

LMS Virtual.Lab System-Level FatigueLMS Virtual.Lab System-Level Fatigue offers a complete solution for optimizing sub-systems or assemblies, and analyzing their strength and fatigue. It allows engineers to calculate component loads from prescribed system motion through multibody simulation, using the embedded LMS Virtual.Lab Motion solver. These component loads are combined with structural stresses. Finally, material fatigue parameters are applied to predict the component fatigue hotspots and corresponding fatigue life.

Its easy-to-use interface with dedicated templates and customized wizards facilitates multibody model set-up. Scalable modeling makes it possible to refi ne models at any time and work with rigid or fl exible component representations. The previously lengthy and error-prone job of integrating a fl exible body now only takes a few mouse clicks. All the user needs to do is pick up the component FE mesh and drag it into the system model. All body connections are automatically established based on detected attachment nodes and degrees of freedom.

LMS Virtual.Lab System-Level Fatigue cascades road profi les down to load responses on the component level. The multibody model is put on a virtual test rig and appropriate boundary conditions for the road profi le are automatically set. For each individual system part, predicted information on dynamic load cases, modal participation factors, excitation locations and local axes confi gurations are automatically transferred to the fatigue-life solver.

The post-processing functions provide fast and critical insights into the load transfer path for the fatigue life of any component. This allows engineers to quickly investigate hotspots and rerun analyses for numerous system-level design variants.


The user selectes the type and the length of the sine sweep...

...within minutes the results may by assessed.

The amplitudes of the sine sweep are defined.For a bracket subjected to a sine sweep, a modal analysis is performed.

LMS Virtual.Lab Vibration Fatigue

Traditionally, fatigue damage is associated with time-dependent loading from local stress or strain histories. In many situations, a description in the frequency domain is more practical.

For example, take the case of a randomly excited shaker table or an active wind turbine, where loading time signals are not easily determined, but described using stationary processes or, engine accessories which are excited by the engine and the loads are defi ned in small frequency bands. Another example would be simulating a complete sine sweep on a virtual shaker table usually handled in the time domain but, for effi ciency reasons, the simulation is best completed in the frequency domain using a harmonic vibration approach.

LMS has solid experience in frequency-based solvers and both component-level and system-level load transfers. With its vibration fatigue solver, LMS combines its leading-edge knowledge with durability assessment methods using frequency-based solvers. Users can easily benefi t from the simple and consistent set-up and highly effi cient analysis methods, including random and deterministic loads in the frequency domain. The solver combines well-known methodology with technology breakthroughs like real multi-axial load and local stress behavior as well as seam and spot weld capabilities for highly accurate results. Post-processing features are adaptable to particular applications to quickly and effi ciently identify critical regions and provide answers to the durability issue.

VL-DUR.23.2

Benefits

Features

Uni & Multi-axial load input (PSDs/• cross-PSDs input for load correlation)Deterministic sine and random loads• High performance (including storage • requirements) for large models & multiple load conditionsMulti-axial local stress states• Durability-centered post-processing•

Reduce time by highly optimized • calculation efficiencyReduce risk by understanding • multiple load conditionsGain insight to critical design issues• Analyze any frequency-based load • Optimal design for fatigue • early in the design phase


Road Profi le Interface The Road Profi le Interface provides a convenient way to make a complex 3D road profi le or surface. The new feature generates geometry for the road surface from 3 different fi le sources. Spline curves, spline surfaces, and the CDTire ROAD 2000 format. The road surface feature is aimed at connecting the analytical road surface used by the solver with the visualized geometry.

OptimizationLMS Virtual.Lab Optimization provides a set of powerful capabilities for single and multi-attribute optimization. Through Design of Experiments (DOE) and Response Surface Modeling (RSM) techniques, engineers gain a rapid insight in all the possible design options that meet their requirements. Using advanced optimization routines including manufacturing for Six Sigma, LMS Virtual.Lab automatically selects the optimal design, taking into account real-world variability and meeting the strictest robustness, reliability and quality criteria.

VL-O

PT.2

2.2

Thermal Fatigue

Environmental temperature and especially changes in the temperature have a signifi cant infl uence on fatigue. On one hand, engineers need to include these effects in the fatigue analysis. On the other hand, material data accounting for these effects are expensive to achieve. This module offers a multi-level approach to achieve a good compromise between accuracy and effi ciency. From simple temperature dependent SN-curves to temperature dependent stress-strain behavior and to creep and oxidation, the user can choose the method matching his problems.

VL-D

UR.

14.3

Seam Weld ModelingSeam-welded components typically have a limited lifespan. Simulating the fatigue behavior of welded structures is key to the design process. Structure loads can be represented as load-time histories or in frequency domain. The module lets users examine multiple loads. This unique seam weld module automatically detects connections between different sheets and classifi es the connection into butt and edge welds, overlap joints and T joints with different angles. Using the information from the fi nite element model the appropriate sheet thickness is assigned. The designer only has to check specifi c manufacturing and welding details.

VL-D

UR.

13.3

VL-D

UR.

12.3

VL-D

MP.

04.3

Spot Weld Modeling

This package contains functionality for fi nding and modifying or creating new spot weld connections in the mesh. It is able to extract spot weld defi nitions from CAD structures and existing meshes directly. New spot welds may be defi ned interactively or automatically. The module supports various spot weld representations from simple bars and hexahedra to Nastran CWELD and fi ne spot weld models for enhanced durability simulations. Spot weld modeling covers fatigue life analysis of spot welds including traditional force-based approaches (Rupp, LBF, and JSAE) as well as local stress-based approaches. A unique and intelligent algorithm combines the ease-of-use and performance of the fi rst approach with the enhanced accuracy of the latter, delivering an ideal balance of performance and accuracy.

LMS Virtual.Lab Durability - OptionsDurability Parallel Processing (Stackable 4-node)

With parallel processing capabilities, LMS fatigue solvers can handle large problems effi ciently. Already in the standard confi guration, larger analysis calculations are split in two processes to take advantage of modern dual core processors. Adding the durability parallel processing option increases the calculation power and drastically decreases calculation times by another 4 processing nodes. This option is stackable, which means that that one can add 8 nodes using simply two licenses. The durability parallel processing option is compatible with the vibration fatigue solver (VL-DUR.23.2) and the FALANCS solver for component and system-level fatigue (VL-DUR.24.2 and VL.DUR.25.2).


LMS INTERNATIONALResearchpark Z1, Interleuvenlaan 68 B-3001 Leuven [Belgium]T +32 16 384 200 | F +32 16 384 [email protected] | www.lmsintl.com

Worldwide For the address of your local representative,

please visit www.lmsintl.com/lmsworldwide

LMS is an engineering innovation partner for companies in the automotive, aerospace and other advanced manufacturing industries. With approximately 30 years of experience, LMS helps customers get better products to market faster and turn superior process efficiency into key competitive advantages.

With a unique combination of 1D and 3D simulation software, testing systems and engineering services, LMS tunes into mission critical engineering attributes, ranging from system dynamics, structural integrity and sound quality to durability, safety and power consumption. With multi-domain solutions for thermal, fluid dynamics, electrical and mechanical system behavior, LMS can address the complex engineering challenges associated with intelligent system design.

Thanks to our technology and dedicated people, LMS has become the partner of choice of more than 5,000 leading manufacturing companies worldwide. LMS is certified to ISO9001:2000 quality standards and operates through a network of subsidiaries and representatives in key locations around the world. For more information on LMS, visit www.lmsintl.com.

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