Introduction to fe-safe®

2017
About this Course

Course objectives
Upon completion of this course you will be able to:

Set up and run various fatigue analyses using fe-safe

Set up models and import models into fe-safe
Select a material for fatigue analysis
Set up your loadings
Run various analyses in fe-safe

Targeted audience
Simulation Analysts

Prerequisites
None

2 days
Day 1

Lesson 1 Overview of Fatigue and fe-safe

Demo 1 A First Look at fe-safe
Lesson 2 fe-safe User Interface
Workshop 1 Signal Processing (Optional)
Lesson 3 Defining Group Parameters
Workshop 2 FEA Fatigue of a Notched Steel Tube
Lesson 4 Theory of Fatigue
Workshop 3 Approximating and Customizing Fatigue Properties of Materials (Optional)
Lesson 5 Loading Methods in fe-safe
Workshop 4 Generating Loading Definitions
Day 2

Lesson 5 Loading Methods in fe-safe (cont’d)

Workshop 5 Generating Complex Loading Definitions
Lesson 6 Fatigue Analysis Process and Algorithms
Workshop 6 Finite Life and Target Life of a Notched Shaft
Lesson 7 fe-safe Diagnostic Techniques
Workshop 7 Exports and Outputs for a Notched Shaft Analysis
Lesson 8 Infinite Life, Probability and Theory of Critical Distances (Optional)
Additional Material

Appendix 1 High Temperature Fatigue Analysis in fe-safe

Appendix 2 Rotational Symmetry of Loading
Appendix 3 Signal Processing with safe4fatigue
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Tosca • Structural and Fluid Flow Optimization Weight, Stiffness, Stress
• Topology, Sizing, Shape, Bead Optimization Pressure Loss Reduction

• Durability Simulation Safety Factors

fe-safe • Low Cycle and High Cycle Fatigue Creep-Fatigue Interaction
• Weld, High Temperature, Non-metallics Weld Fatigue

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Legal Notices

The software described in this documentation is available only under license from Dassault Systèmes
or its subsidiaries and may be used or reproduced only in accordance with the terms of such license.
This documentation and the software described in this documentation are subject to change without
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Revision Status

Lesson 1 11/16 Updated for fe-safe 2017

Lesson 2 11/16 Updated for fe-safe 2017
Lesson 3 11/16 Updated for fe-safe 2017
Lesson 4 11/16 Updated for fe-safe 2017
Lesson 5 11/16 Updated for fe-safe 2017
Lesson 6 11/16 Updated for fe-safe 2017
Lesson 7 11/16 Updated for fe-safe 2017
Lesson 8 11/16 Updated for fe-safe 2017
Workshop 1 11/16 Updated for fe-safe 2017
Workshop 2 11/16 Updated for fe-safe 2017
Workshop 3 11/16 Updated for fe-safe 2017
Workshop 4 11/16 Updated for fe-safe 2017
Workshop 5 11/16 Updated for fe-safe 2017
Workshop 6 11/16 Updated for fe-safe 2017
Workshop 7 11/16 Updated for fe-safe 2017
Appendix 1 11/16 Updated for fe-safe 2017
Appendix 2 11/16 Updated for fe-safe 2017
Appendix 3 11/16 Updated for fe-safe 2017
 L1.1
Lesson 1: Overview of Fatigue and fe-safe

Lesson content:

Overview of Fatigue
FEA Fatigue
Overview of fe-safe
Add-on Modules, Extensions and Partner Products
www.3ds.com | © Dassault Systèmes

Summary
Demonstration 1: A First Look at fe-safe

45 minutes
 L2.1
Lesson 2: fe-safe User Interface

Lesson content:

Starting fe-safe

GUI Components

Logging
www.3ds.com | © Dassault Systèmes

Loaded Data Files Window

Material Databases Window

Current FE Models Window

Project Directory

Analysis Options

Workshop 1: Signal Processing (Optional)

60 Minutes
 L3.1
Lesson 3: Defining Group Parameters

Lesson content:

Group Parameters
Analysis Subgroup
Surface Finish
Material Designation
www.3ds.com | © Dassault Systèmes

Fatigue Algorithms
In-plane Residual Stress
SN Scale
SN Data Knock-Down Curve
Workshop 2: FEA Fatigue of a Notched Steel Tube

30 Minutes
 L4.1
Lesson 4: Theory of Fatigue

Lesson content:

Three Stages of Fatigue Failure

Early Examples of Fatigue Testing
Load History with Two Blocks of Constant Amplitude
Variable Amplitude Loading
www.3ds.com | © Dassault Systèmes

Effects of Variable Amplitude Loading

Effect of Mean Stress on Fatigue Life
Stress-based Fatigue
Strain-based Fatigue
Surface Finish
In-plane Residuals
Material Approximation
Workshop 3: Approximating and Customizing Fatigue Properties of Materials (Optional)

45 Minutes
 L5.1
Lesson 5: Loading Methods in fe-safe

Lesson content:

Loading Methods in fe-safe

Single Load History (Scale-and-Combine Loading)
Component with Multiple Load Histories
A Sequence of Stresses from the FE Analysis
Frequency-based Fatigue Loading
www.3ds.com | © Dassault Systèmes

Summary of Basic Loading Definitions

Workshop 4: Generating Loading Definitions
Multiple Block Loading
Load Block Transitions
Additional Loading Capabilities
Conventional High Temperature Fatigue
Residual Stress Dataset Pair
Superposition of High and Low Frequency Loads
Summary
Workshop 5: Generating Complex Loading Definitions

1 hour
 L6.1
Lesson 6: Fatigue Analysis Process and Algorithms

Lesson content:

fe-safe Analysis Process

Damage Parameters
Out-of-phase Biaxial Stresses
Critical Plane Methods
www.3ds.com | © Dassault Systèmes

Mean Stress Corrections

Fatigue Algorithms
Strain-based Fatigue Algorithms
Stress-based Fatigue Algorithms
Uniaxial Fatigue Algorithms
Advanced Fatigue Algorithms
Factor of Strength
Workshop 6: Finite Life and Target Life of a Notched Shaft

1 hour
 L7.1
Lesson 7: fe-safe Diagnostic Techniques

Lesson content:

Diagnostic Techniques

Source File

Exports and Outputs

www.3ds.com | © Dassault Systèmes

Gauges and Influence Coefficients

Hotspot Detection

Workshop 7: Exports and Outputs for a Notched Shaft Analysis

45 Minutes
 L8.1
Lesson 8: Infinite Life, Probability and Theory of Critical Distances

Lesson content:

Infinite Life Algorithms

Design Target and Probability Calculations

Fatigue Reserve Factor Analysis

www.3ds.com | © Dassault Systèmes

Theory of Critical Distances

Theory of Critical Distances Testing

Failure Rate for Target Lives

45 Minutes
 A1.1
Appendix 1: High Temperature Fatigue Analysis in fe-safe

Appendix content:

Background
High Temperature Fatigue Methods
Conventional High Temperature Fatigue in fe-safe
Conventional High Temperature Fatigue Example
www.3ds.com | © Dassault Systèmes

Creep – Fatigue
fe-safe/TURBOlife Overview
Interpolation and Extrapolation of Sparse Data Tables in fe-safe
fe-safe/TURBOlife Ductility Exhaustion
fe-safe/TURBOlife Ductility Exhaustion Example
fe-safe/TURBOlife Strain Range Partitioning
fe-safe/TURBOlife Strain Range Partitioning Example
fe-safe/TURBOlife Concluding Comments

45 Minutes
 A2.1
Appendix 2: Rotational Symmetry of Loading

Appendix content:

fe-safe®/Rotate
fe-safe/Rotate Example
Using fe-safe/Rotate
www.3ds.com | © Dassault Systèmes

20 Minutes
 A3.1
Appendix 3: Signal Processing with safe4fatigue

Appendix content:

Signal Processing – safe4fatigue

Strain Gauge Fatigue

Exporting a Simulated Strain Gauge Reading from fe-safe®

www.3ds.com | © Dassault Systèmes

Using fe-safe to Design and Validate Test Command Signals

Intermittent Contact Conditions

20 minutes