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Knowledge Base Search Knowledge Base User Manuals [Document #82125]
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OptiStruct User Guide 13.0 User's Guide Fatigue Analysis Fatigue Analysis

Fatigue Analysis
Fatigue analysis, using S-N (stress-life), E-N (strain-life), and Dang Van Criterion
(Factor of Safety) approaches for predicting the life (number of loading cycles) of a
structure under cyclical loading may be performed by using OptiStruct.
The stress-life method works well in predicting fatigue life when the stress
level in the structure falls mostly in the elastic range. Under such cyclical
loading conditions, the structure typically can withstand a large number of

loading cycles; this is known as high-cycle fatigue. When the cyclical strains
extend into plastic strain range, the fatigue endurance of the structure
typically decreases significantly; this is characterized as low-cycle
fatigue. The generally accepted transition point between high-cycle and lowcycle fatigue is around 10,000 loading cycles. For low-cycle fatigue
prediction, the strain-life (E-N) method is applied, with plastic strains being
considered as an important factor in the damage calculation.
Sections of a model on which fatigue analysis is to be performed must be identified on
a FATDEF bulk DATA ENTRY . The appropriate FATDEF bulk data entry may be referenced
from a fatigue subcase definition through the FATDEF Subcase Information entry.
The Dang Van criterion is used to predict if a component will fail in its entire
load history. The conventional fatigue result that specifies the minimum
fatigue cycles to failure is not applicable in such cases. It is necessary to
consider if any fatigue damage will occur during the entire load history of the
component. If damage does occur, the component cannot experience infinite
life.
The Stress-Life (S-N) Approach

S-N Curve
The S-N curve, first developed by Whler, defines a relationship between stress and number of
cycles to failure. Typically, the S-N curve (and other fatigue properties) of a material is obtained
from experiment; through fully reversed rotating bending tests. Due to the large amount of
scatter that usually accompanies test results, statistical characterization of the data should also be
provided (certainty of survival is used to modify the S-N curve according to the standard error of
the curve and a higher reliability level requires a larger certainty of survival).

Figure 1: S-N data from testing

When S-N testing data is presented in a log-log plot of alternating nominal stress amplitude Sa or
range SR versus cycles to failure N, the relationship between S and N can be described by straight

line segments. Normally, a one or two segment idealization is used.

Figure 2: One segment S-N curves in log-log scale

for segment 1

(1)

Where,
S is the nominal stress range
Nf are the fatigue cycles to failure
b1 is the first fatigue strength exponent
S1 is the fatigue strength coefficient

The S-N approach is based on elastic cyclic loading, inferring that the S-N curve should be
confined, on the life axis, to numbers greater than 1000 cycles. This ensures that no significant
plasticity is occurring. This is commonly referred to as high-cycle fatigue.
S-N curve data is provided for a given material on a MATFAT bulk DATA ENTRY . It is
referenced through a Material ID (MID) which is shared by a structural material definition.

Damage Model
Palmgren-Miner's linear damage summation rule is used. Failure is predicted when:

(2)

Where,

Nif is the materials fatigue life (number of cycles to failure) from its S-N
curve at a combination of stress amplitude and means stress level i
ni is the number of stress cycles at load level i
Di is the cumulative damage under ni load cycle
The linear damage summation rule does not take into account the effect of the load sequence on
the accumulation of damage due to cyclic fatigue loading. However, it has been proved to work
well for many applications.

Cycle Counting
Cycle counting is used to extract discrete simple "equivalent" constant amplitude cycles from a
random loading sequence. One way to understand cycle counting is as a changing stress-strain
versus time signal. Cycle counting will count the number of stress-strain hysteresis loops and
keep track of their range/mean or maximum/minimum values.
Rainflow cycle counting is the most widely used cycle counting method. It requires that the
stress time history be rearranged so that it contains only the peaks and valleys and it starts either
with the highest peak or the lowest valley (whichever is greater in absolute magnitude). Then,
three consecutive stress points (S1, S2, and S3) will define two consecutive ranges as S1 = |S1 S2| and S2 = |S2 - S3| . A cycle from S1 to S2 is only extracted if S1
S2. Once a cycle is
extracted, the two points forming the cycle are discarded and the remaining points are connected
to each other. This procedure is repeated until the remaining data points are exhausted.

Figure 3: Determine cycles using rainflow cycle counting method

Parameters affecting rainflow cycle counting may be defined on a FATPARM bulk DATA
ENTRY . The appropriate FATPARM bulk DATA ENTRY may be referenced from a fatigue
subcase definition through the FATPARM Subcase Information entry.

Equivalent Nominal Stress

Since S-N theory deals with uniaxial stress, the stress components need to be resolved into one
combined value for each calculation point, at each time step, and then used as equivalent
nominal stress applied on the S-N curve.
Various stress combination types are available with the default being Absolute maximum
principle stress. In general Absolute maximum principle stress is recommended for brittle
materials, while Signed von Mises stress is recommended for ductile material. The sign on the
signed parameters is taken from the sign of the Maximum Absolute Principal value.
Parameters affecting stress combination may be defined on a FATPARM bulk data entry. The
appropriate FATPARM bulk data entry may be referenced from a fatigue subcase definition
through the FATPARM Subcase Information entry.

Mean Stress Influence

Generally S-N curves are obtained from standard experiments with fully reversed cyclic
loading. However, the real fatigue loading could not be fully reversed and the normal mean
stresses have significant effect on fatigue performance of components. Tensile normal mean
stresses are detrimental and compressive normal mean stresses are beneficial, in terms of fatigue
strength. Mean stress correction is used to take into account the effect of non-zero mean stresses.
The Gerber parabola and the Goodman line in Haigh's coordinates are widely
used when considering mean stress influence, and can be expressed as:

Gerber:

Goodman:

(3)

(4)

Where,
Mean stress Sm = (Smax + Smin) / 2
Stress amplitude Sa = (Smax - Smin) / 2
Se is the stress range for fully reversed loading that is equivalent to the

load case with a stress range SR and a mean stress Sm

Su is ultimate strength

The Gerber method treats positive and negative mean stress correction in
the same way that mean stress always accelerates fatigue failure, while the
Goodman method ignores the negative means stress. Both methods give

conservative result for compressive means stress. The Goodman method is

recommended for brittle material while the Gerber method is recommended
for ductile material. For the Goodman method, if the tensile means stress is
greater than UTS, the damage will be greater than 1.0. For Gerber method,
if the mean stress is greater than UTS, no matter tensile or compressive, the
damage will be greater than 1.0.
A Haigh diagram characterizes different combinations of stress amplitude and mean stress for a
given number of cycles to failure.

Figure 4: Haigh diagram and mean stress correction methods

Parameters affecting mean stress influence may be defined on a FATPARM bulk DATA
ENTRY . The appropriate FATPARM bulk data entry may be referenced from a fatigue
subcase definition through the FATPARM Subcase Information entry.

The Strain-Life (E-N) Approach

Monotonic Stress-Strain Behavior

Relative to the current configuration, the true stress and strain relationship can be defined as:
(5)

(6)

Where, A is the current cross-section area, l is the current specimen

length, l0 is the initial specimen length, and and
are the true stress and
strain, respectively, Figure 5 shows the monotonic stress-strain curve in
true stress-strain space. In the whole process, the stress continues

increasing to a large value until the specimen fails at C.

Figure 5: Monotonic stress-strain curve

The curve in Figure 5 is comprised of two typical segments, namely the

elastic segment OA and plastic segment AC. The segment OA keeps the
linear relationship between stress and elastic strain following Hooke Law:
(7)
Where, E is elastic modulus and
rewritten as:

is elastic strain. The formula can also be

(8)

by expressing elastic strain in terms of stress. For most of materials, the

relationship between the plastic strain and the stress can be represented by
a simple power law of the form:
(9)
Where,
is plastic strain, K is strength coefficient, and n is work hardening
coefficient. Similarly, the plastic strain can be expressed in terms of stress
as:
(10)
The total strain induced by loading the specimen up to point B or D is the
sum of plastic strain and elastic strain:
(11)

Cyclic Stress-Strain Curve

Material exhibits different behavior under cyclic load compared with that of
monotonic load. Generally, there are four kinds of response.
stable state
cyclically hardening
cyclically softening
softening

or hardening depending on strain range

Which response will occur depends on its nature and initial condition of heat
treatment. Figure 6 illustrates the effect of cyclic hardening and cyclic
softening where the first two hysteresis loops of two different materials are
plotted. In both cases, the strain is constrained to change in fixed range,
while the stress is allowed to change arbitrarily. If the stress range
increases relative to the former cycle under fixed strain range, as shown in
the upper part of Figure 6, it is called cyclic hardening; otherwise, it is
called cyclic softening, as shown in the lower part of Figure 6. Cyclic
response of material can also be described by specifying the stress range
and leaving strain unconstrained. If the strain range increases relative to
the former cycle under fixed stress range, it is called cyclic softening;
otherwise, it is called cyclic hardening. In fact, the cyclic behavior of
material will reach a steady state after a short time which generally occupies
less than 10 percent of the material total life. Through specifying different
strain ranges, a series of hysteresis loops at steady state can be
obtained. By placing these hysteresis loops in one coordinate system, as
shown in Figure 7, the line connecting all the vertices of these hysteresis
loops determine cyclic stress-strain curve which can be expressed in the
similar form with monotonic stress-strain curve as:

Figure 6: Material cyclic response (a) Cyclic hardening; (b) Cyclic softening

Figure 7: Definition of stable stress-strain curve

(12)
Where, K' is cyclic strength coefficient, n' is strain cyclic hardening exponent.

Hysteresis Loop Shape

Bauschinger observed that after the initial load had caused plastic strain,
load reversal caused materials to exhibit anisotropic behavior. Based on
experiment evidence, Massing put forward the hypothesis that a stressstrain hysteresis loop is geometrically similar to the cyclic stress strain
curve, but with twice the magnitude. This implies that when the
quantity
is two times of
, the stress-strain cycle will lie on the
hysteresis loop. This can be expressed with formulas:
(13)
(14)
Expressing
in terms of
,
in terms of
, and substituting it into Eq.
12, the hysteresis loop formula can be deduced as:
(15)

Strain-Life Approach
Almost a century ago, Basquin observed the linear relationship between
stress and fatigue life in log scale when the stress is limited. He put forward
the following fatigue formula controlled by stress:
(16)
Where,
is stress amplitude,
fatigue strength coefficient, b fatigue
strength exponent. Later in the 1950s, Coffin and Manson independently
proposed that plastic strain may also be related with fatigue life by a simple
power law:
a

(17)
Where,
is plastic strain amplitude,
fatigue ductility coefficient, c fatigue
ductility exponent. Morrow combined the work of Basquin, Coffin and
Manson to consider both elastic strain and plastic strain contribution to the
fatigue life. He found out that the total strain has more direct correlation
with fatigue life. By applying Hooke Law, Basquin rule can be rewritten as:
(18)
Where,
is elastic strain amplitude. Total strain amplitude, which is the
sum of the elastic strain and plastic stain, therefore, can be described by
applying Basquin formula and Coffin-Manson formula:
(19)
Where, is the total strain amplitude, the other variable is the same with
above. Figure 8 illustrates three methods in log scale in stress-life
space. Two straight lines, which represent Basquin formula and CoffinManson rule respectively, intersect at a point where elastic strain is equal to
the plastic strain and the fatigue life predicted by the two methods is the
same. The fatigue life at the intersection point is called transition life and
can be calculated as:
(20)
by combining Eq.17 and Eq.18, at the same time, applying the conditions:

(21)
(22)
Where, Nt is the transition life. When fatigue life is less than the transition
life, plastic strain plays the controlling role in life prediction; otherwise,
elastic strain plays the key role.

Figure 8: Strain-life curve in log scale

Damage Accumulation Model

In the E-N approach, use the same damage accumulation model as the S-N
approach, which is Palmgren-Miner's linear damage summation rule.

Mean Stress Influence

The fatigue experiments carried out in the laboratory are always fully
reversed, whereas in practice, the mean stress is inevitable, thus the fatigue
law established by the fully reversed experiments must be corrected before
applied to engineering problems. Morrow is the first to consider the effect of
mean stress through introducing the mean stress
in fatigue strength
coefficient by:
0

(23)
Thus the entire fatigue life formula becomes:
(24)
Morrow's equation is consistent with the observation that mean stress

effects are significant at low value of plastic strain and of little effect at high
plastic strain.
Smith, Watson and Topper proposed a different method to account for the
effect of mean stress by considering the maximum stress during one cycle
(for convenience, this method is called SWT in the following). In this case,
the damage parameter is modified as the product of the maximum stress
and strain range in one cycle. For a fully reversed cycle, the maximum stress
is given by:
(25)
By multiplying Eq.19 with Eq.25, it can be rewritten as:
(26)
The SWT method will predict that no damage will occur when the maximum
stress is zero or negative, which is not consistent with the reality.
When comparing the two methods, the SWT method predicted conservative
life for loads predominantly tensile, whereas, the Morrow approach provides
more realistic results when the load is predominantly compressive.

Neuber Correction
Strain-life analysis is based on the fact that many critical locations such as
notch roots have stress concentration, which will have obvious plastic
deformation during the cyclic loading before fatigue failure. Thus, the elasticplastic strain results are essential for performing strain-life analysis. Neuber
correction is the most popular practice to correct elastic analysis results into
elastic-plastic results.
In order to derive the local stress from the nominal stress that is easier to
obtain, the concentration factors are introduced such as the local stress
concentration factor
, and the local strain concentration factor
.
(27)
(28
)
Where, is the local stress, is the local strain, S is the nominal stress, and e is
the nominal strain. If nominal stress and local stress are both elastic, the
local stress concentration factor is equal to the local strain concentration
factor. However, if the plastic strain is present, the relationship between
and
no long holds. Thereafter, focusing on this situation, Neuber
introduced a theoretically elastic stress concentration factor Kt defined as:

(29)
Substitute Eq.27 and Eq.28 into Eq.29, the theoretical stress concentration
factor Kt can be rewritten as:
(30)
Through linear static FEA, the local stress instead of nominal stress is
provided, which implies the effect of the geometry in Eq.30 is removed, thus
you can set Kt as 1 and rewrite Eq.30 as:
(31)
Where, ,
is locally elastic stress and locally elastic strain obtained from
elastic analysis, , the stress and strain at the presence of plastic
strain. Both and
can be calculated from Eq.31 together with the
equations for the cyclic stress-strain curve and hysteresis loop.
e

Dang Van Criterion (Factor of Safety)

The Dang Van criterion is used to predict if a component will fail in its entire
load history. In certain physical systems, components may be required to
last infinitely long. For example, automobile components which undergo
multiaxial cyclic loading at high rotational velocities (like propeller shafts)
reach their high cycle fatigue limit within a short operating life. The
conventional fatigue result that specifies the minimum fatigue cycles to
failure is not applicable in such cases. It is not necessary to quantify the
amount of fatigue damage, but just to consider if any fatigue damage will
occur during the entire load history of the component. If damage does occur,
the component cannot experience infinite life. Fatigue analysis based on the
Dang Van criterion is designed for this purpose.
Fatigue crack initiation usually occurs at zones of stress concentration such
as geometric discontinuities, fillets, notches and so on. This phenomenon
takes place in the microscopic level and is localized to certain regions like
grains which have undergone local plastic deformation in characteristic intracrystalline bands. The Dang Van approach postulates a fatigue criterion
using microscopic variables in the apparent stabilization state; this is a state
of elastic shakedown if no damage occurs. The main principle of the criterion
is that the usual characterization of the fatigue cycle is replaced by the local
loading path and so damaging loads can be distinguished.
The general procedure of Dang Van fatigue analysis is:

1.Evaluate the macroscopic

2.Split

stresses

the macroscopic stress

3.Calculate

, for each location at a different point in time.

into a hydrostatic part

the stabilized microscopic residual stress

The expression is minimized with respect to

and a deviatoric part

based on the following equation:

and maximized with respect to t.

4.Calculate

the deviatoric part of microscopic stress.

5.Calculate

factor of safety (FOS):

Where, b and a are material constants.

If FOS is less than 1, the component cannot experience infinite life.

OptiStruct Factor of Safety setup

1.The torsion

fatigue limit and hydrostatic stress sensitivity values required for an FOS analysis
can be set in the optional FOS continuation line on the MATFAT bulk DATA ENTRY .
2.The Dang Van
3.Factor

criterion type can be selected on the FATPARM bulk DATA ENTRY .

of Safety output can be requested using the FOS I/O options entry.

Other Factors Affecting Fatigue

Surface Condition (Finish and Treatment)

Surface condition is an extremely important factor influencing fatigue
strength, as fatigue failures nucleate at the surface. Surface finish and
treatment factors are considered to correct the fatigue analysis results.
Surface finish correction factor Cfinish is used to characterize the roughness of
the surface. It's presented on diagrams that categorize finish by means of
qualitative terms such as polished, machined or forged.

Figure 9*: Surface finish correction factor for steels

(* Source: Yung-Li Lee, Jwo. Pan, Richard B. Hathaway and Mark E. Barekey. Fatigue testing and analysis:
Theory and practice, Elsevier, 2005)

Surface treatment can improve the fatigue strength of components.

NITRIDED, SHOT-PEENED, COLD-ROLLED are considered for surface
treatment correction. It is also possible to input a value to specify the
surface treatment factor Ctreat.
In general cases, the total correction factor is Csur = Ctreat * Cfinish.
If treatment type is NITRIDED, then the total correction
is Csur = 2.0 * Cfinish (Ctreat = 2.0).
If treatment type is SHOT-PEENED or COLD-ROLLED, then the total
correction is Csur = 1.0. It means you will ignore the effect of surface finish.
The fatigue endurance limit FL will be modified by Csur as: FL' = FL * Csur. For
two segment S-N curve, the stress at the transition point is also modified by
multiplying by Csur.
Surface conditions may be defined on a PFAT bulk DATA ENTRY . Surface
conditions are then associated with sections of the model through the FATDEF bulk DATA
ENTRY .

Fatigue Strength Reduction Factor

In addition to the factors mentioned above, there are various others factors
that could affect the fatigue strength of a structure, e.g., notch effect, size
effect, loading type. Fatigue strength reduction factor Kf is introduced to
account for the combined effect of all such corrections. The fatigue
endurance limit FL will be modified by Kf as: FL' = FL / Kf

The fatigue strength reduction factor may be defined on a PFAT bulk DATA
ENTRY . It may then be associated with sections of the model through the FATDEF bulk data
entry.
If both Csur and Kf are specified, the fatigue endurance limit FL will be
modified as: FL' = FL * Csur / Kf.
Csur and Kf have similar influences on the E-N formula through its elastic part
as on the S-N formula. In the elastic part of the E-N formula, a nominal
fatigue endurance limit FL is calculated internally from the reversal limit of
endurance Nc. FL will be corrected if Csurand Kf are presented. The elastic part
will be modified as well with the updated nominal fatigue limit.
Setting Up a Fatigue Analysis

Linear Superposition of Multiple FEA/Load Time History Load

Cases
When there are several load cases at the same time, all of which vary
independently of one another, the principle of linear superposition will be
used to combine all load cases together to determine the stress variation at
each calculation point due to the combination of all loads. The formula is:

(32)

Where,
n is the total number of load cases
Pk(t) and
are, respectively, the time variation of the k-th load time
history and the total stress tensor
PFEA,k and
are, respectively, the k-th load magnitude and stress tensor
from FE analysis

Load Time History Compression

This option is used to save calculation time. It will remove small cycles
(defined by a gate value) and intermediate points.

Figure 10: Sample showing removal of small cycles

When removing small cycles, adjacent turning points, where the difference is
less than the maximum range multiplied by relative gate value, will be
removed from each channel. However, phase relationship will be
maintained, when peaks and valleys occur on different channels at different
times. This is shown by the sample above. In the first channel (top), the
points at time 4 and 5 will be removed when the absolute gate equals one,
while in the second channel (bottom), the points at time 1 and 2 will not be
removed in order to keep the phase relationship between channels.

Figure 11: Sample showing removal of intermediate points

Removing intermediate points is another important mechanism to save

computation time. If any point on the load-time history is neither a peak
nor valley point, it will not contribute in determining any stress cycle. Such
points could be screened out in the fatigue computation without losing the
accuracy, but the computation time could be saved significantly. For
example, the left column in Fig 11 shows three load-time histories of three
super-positioned loadcases, respectively. After removing the intermediate
points, the three load-time histories are obtained as in the right column,
which can produce the same fatigue results as the left column, but use much
less time. This mechanism is built in OptiStruct and is effective automatically.

Fatigue Loads, Events and Sequences

Fatigue loading is defined by scaling a static subcase with a load-time
history.
A fatigue event consists of one or more static loadcases applied
simultaneously in the same time duration scaled by load-time histories. For
fatigue events with more than one static loadcase stress, linear
superposition is used.
A fatigue sequence consists of a number of fatigue events and repeated
instances of these events. A fatigue sequence can be made up of other sub

fatigue sequences and/or fatigue events. In this way, you can define very
complex events and sequences for fatigue analysis.
In OptiStruct, fatigue sequences defined in fatigue subcases (referred by
FATSEQ) are the basic loading blocks. The fatigue life results of these fatigue
subcases are calculated as the number of repeats of the loading block.
Below is an example of a "tree-like" fatigue sequence, which can be defined
in OptiStruct, with FSEQ# identifying fatigue sequences and FEVN# identifying
fatigue events:

Figure 12: Example of a "tree-like" fatigue sequence

Fatigue loading is defined by a FATLOAD bulk DATA ENTRY , where a static

subcase and a load-time history are associated.
A fatigue loading event is defined by a FATEVNT bulk DATA ENTRY , where
one or more fatigue loads (FATLOAD) are selected.
A fatigue loading sequence is defined by a FATSEQ bulk DATA ENTRY ,
where a sequence of one or more fatigue loading events or other fatigue
loading sequences is given. The appropriate FATSEQ bulk data entry may be
referenced from a fatigue subcase definition through the FATSEQ Subcase
Information entry.

Fatigue Analysis
Product:

Index

Multi-body Dynamics Simulation

OptiStruct
Stats:
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