M ichael Klein

INTES GmbH, Stuttgart, Germany



Fatigue analysis is established in industrial applications. The findings are used for the design of components in lightweight construction.
The classic fatigue analysis leads to additional requirements for the simulation process. The exchange of large amounts of data between software/compute servers with different interface formats is necessary. The implementation and error-free use of this process is the responsibility of the user. In addition to data handling, the different release periods of the software involved must also be considered.
The full integration of the fatigue analysis into a general FEM solver solves the process issue. Both parts of the analysis, the classic stress analysis, and the fatigue analysis, are based on a common data model and use the same resources. This ensures data efficiency (large data stays internal, double data handling is avoided) and the import/export of intermediate results is no longer necessary.
Stress gradients, previously additionally calculated by the fatigue software based on its own model data, are now available in better quality directly within the FEM software based on the original FEM model. This can be used to increase the quality of results. Due to the elimination of data exchange and the HPC orientation of the FEM software, the integrated fatigue analysis benefits significantly in terms of performance.
New analysis classes are made possible by reduced amounts of data. Thanks to the integration, the complete stress results for all calculation steps no longer must to be saved, but are used directly ("on-the-fly") by the fatigue analysis in each calculation step and then immediately deleted again. This significant process improvement means that new classes of model variables and significantly more result steps can be considered. The results are then much more accurate.

The new integrated fatigue life analysis improves the process by orders of magnitude. A robust process means process reliability. Stress calculation and fatigue life analysis are integrated in one software and do not require any interfaces. Therefore, there are no complications with data management. Accuracy is increased through improved accuracy for the stress gradients and run time has been drastically reduced.
Basic technology and infrastructure for fatigue analysis in the FEM solver is developed, a perfect starting point for functional expansion, like extension by further fatigue approaches, optimization with damage as objective functions and design constraints. Integration, process reliability and short run times allow the industrial usage of fatigue optimization and sampling.


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