Altair HyperLife 2019

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Intellectual Property Rights Notice p.iii

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HyperLife Tutorials
Intellectual Property Rights Notice p.iv

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Technical Support
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HyperLife Tutorials
Technical Support p.vi

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Contents
Intellectual Property Rights Notice.............................................................................i
Technical Support............................................................................................................v

1 Uniaxial Fatigue Analysis............................................................................................8

1.1 Stress-Life (S-N) Approach........................................................................................... 9

1.2 Strain-Life (E-N) Approach..........................................................................................19

2 Multiaxial Fatigue Analysis....................................................................................... 28

2.1 Stress-Life (S-N) Approach......................................................................................... 29

2.2 Strain-Life (E-N) Approach..........................................................................................38
2.3 Factor of Safety (FOS)............................................................................................... 47

3 Weld Fatigue Analysis............................................................................................... 53

3.1 Spot Weld (CBAR)..................................................................................................... 54

3.2 Seam Weld (Fillet)..................................................................................................... 63

4 Transient Fatigue Analysis....................................................................................... 74

4.1 Stress-Life (S-N) Approach......................................................................................... 75

Index.................................................................................................................................. 83

7
Uniaxial Fatigue Analysis 1
1 Uniaxial Fatigue Analysis

Uniaxial Fatigue Analysis, using S-N (stress-life) and E-N (strain-life) approaches for predicting the life
(number of loading cycles) of a structure under cyclical loading may be performed by using HyperLife.

This chapter covers the following:

• 1.1 Stress-Life (S-N) Approach (p. 9)

• 1.2 Strain-Life (E-N) Approach (p. 19)
HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.9

1.1 Stress-Life (S-N) Approach

In this tutorial you will:
• Import a model to HyperLife
• Select the SN module and define its required parameters
• Assign materials
• Assign load histories for scaling the stresses from FEA subcases
• Evaluate and view results

Prior to running through this tutorial, copy Models-h3d.zip from

<HyperWorks_installation_directory>\tutorials\hl to a local directory. Extract Shaft.h3d,
load1.csv, and load2.csv from Models-h3d.zip..

1.1.1 Import the Model

1. From the Home tools, Files tool group, click the Open Model tool.

Figure 1:

2. From the Load model and result dialog, browse and select Shaft.h3d for the model file.
The Load result field is automatically populated. For this tutorial, the same file is used for both the
model and the result.
3. Click Apply.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.10

Figure 2:

Tip: Quickly import the model by dragging and dropping the h3d file from a windows
browser into the HyperLife modeling window.

1.1.2 Define the Fatigue Module

1. From the Setup tools, click the SN tool.
The SN tool should be the default fatigue module selected. If it is not, click the arrow next to the
fatigue module icon to display a list of available options.

Figure 3:

The SN dialog opens.

2. Define the SN configuration parameters.
a) Select Uni Axial as the method.
b) Select MPA for the FE model units.
c) Select Signed von for the stress combination.
d) Enter a value of 0.5 for the certainty of survival.
e) Select GOODMAN for the mean stress connection.
f) Select Top for the layer selection.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.11

Figure 4:

3. Exit the dialog.

1.1.3 Assign Materials

1. From the Setup tools, click the Material tool.

Figure 5:

The Assign Material dialog opens.

2. Activate the checkbox next to the part solid.
3. If Steel 1045, Annealed, BHN=225 (932) is not the default material assigned to the part:
a) Click the Material DB tab.
b) Right-click on Steel 1045, Annealed, BHN=225 (932) and select Add to Assign Material
List.
c) Return to the Assign Material Data tab and select Steel 1045, Annealed, BHN=225
(932) from the Material drop-down menu.
The Material list is populated with the materials selected from Material Database and My
Material.
4. Optional: Click to review the SN plot.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.12

Figure 6:

5. Accept all other default parameters.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.13

Figure 7:

Note: The FL (Fatigue Limit) and SE (Standard Error) values are from the SN curve
selected for the part. The SE value can be edited from both the Assign Material Data
tab and the My Material tab. The FL value can be reviewed and edited from the My
Material tab. Parameters updated in the My Material tab will be saved to a user-defined
excel spreadsheet.

6. Exit the dialog.

1.1.4 Assign Load Histories

1. From the Setup tools, click the Load Map tool.

Figure 8:

The Load Map dialog opens.

2. From the Load Type menu, select Time Data.
3. Click and browse for load1.csv.
4. Click to add the load case.

5. Repeat steps 3 and 4 for load2.csv.

6. Optional: Click to view a plot of the loads.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.14

Figure 9: Load 1

Figure 10: Load 2

Tip: Expand the width of the dialog to view a clearer picture of the plot.

7. On the bottom half of the dialog, set the radio button to Manual for event creation and click

to create an Event_1 header.

8. Drag and drop Subcase 1 and Subcase 2 under Event_1.
9. Drag and drop the Block file under load1 onto the Channels field of Subcase 1.
10. Repeat for the Block file under load2 and Subcase 2.
11. Activate the check box for Event_1.
12. Set LDM to 1.0, Scale to 5.0 and Offset to 0.0 for both subcases.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.15

Figure 11:

13. Exit the dialog.

1.1.5 Evaluate and View Results

1. From the Evaluate tool group, click the Run Analysis tool.

Figure 12:

The Evaluate dialog opens.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.16

Figure 13:

2. Optional: Enter a name for the run.

3. Click Run.
Result files are saved to the home directory and the Run History dialog opens.

Figure 14:

4. Once the run is complete, click View Current Results.

5. Use the Results Explorer to visualize various types of results.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.17

Figure 15:

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.18

Figure 16:

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.19

1.2 Strain-Life (E-N) Approach

In this tutorial you will:

• Import a model to HyperLife
• Select the EN module and define its required parameters
• Create and assign a material
• Assign load histories for scaling the stresses from FEA subcases
• Evaluate and view results

Prior to running through this tutorial, copy Models-h3d.zip from

<HyperWorks_installation_directory>\tutorials\hl to a local directory. Extract Hook.h3d,
load1.csv, and load2.csv from Models-h3d.zip..

1.2.1 Import the Model

1. From the Home tools, Files tool group, click the Open Model tool.

Figure 17:

2. From the Load model and result dialog, browse and select Hook.h3d for the model file.
The Load result field is automatically populated. For this tutorial, the same file is used for both the
model and the result.
3. Click Apply.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.20

Figure 18:

Tip: Quickly import the model by dragging and dropping the h3d file from a windows
browser into the HyperLife modeling window.

1.2.2 Define the Fatigue Module

1. From the Setup tools, click the arrow next to the fatigue module icon and select the EN tool from
the list of options.

Figure 19:

The EN dialog opens.

2. Define the EN configuration parameters.
a) Select Uni Axial as the method.
b) Select MPA for the FE model units.
c) Select Signed von for the stress combination.
d) Enter a value of 0.5 for the certainty of survival.
e) Select SWT for the mean stress correction.
f) Select NEUBER for the plasticity stress connection.
g) Select Top for the layer selection.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.21

Figure 20:

3. Exit the dialog.

1.2.3 Assign Materials

1. From the Setup tools, click the Material tool.

Figure 21:

The Assign Material dialog opens.

2. Activate the checkbox next to the part HOOK_solid.
3. Click the My Material tab.
4. Click .
A new material named Mat_EN("n") is created.
5. Set the Standard error of Log(N) from elastic strain and from plastic strain to 0.0 then click Plot
& Save.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.22

Figure 22:

6. Right-click on the newly created material and select Add to Assign Material List.
7. Click the Assign Material Data tab.
8. For HOOK_solid, select Mat_EN("n") from the Material drop-down menu.

Tip: Preview the EN plot by clicking .

9. Accept the default parameters in the Assign Material Data tab.

Figure 23:

10. Exit the dialog.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.23

1.2.4 Assign Load Histories

1. From the Setup tools, click the Load Map tool.

Figure 24:

The Load Map dialog opens.

2. From the Load Type menu, select Time Data.
3. Click and browse for load1.csv.
4. Click to add the load case.

5. Repeat steps 3 and 4 for load2.csv.

6. Optional: Click to view a plot of the loads.

Figure 25: Load 1

Figure 26: Load 2

Tip: Expand the width of the dialog to view a clearer picture of the plot.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.24

7. On the bottom half of the dialog, set the radio button to Manual for event creation and click

to create an Event_1 header.

8. Drag and drop Subcase 1 and Subcase 2 under Event_1.
9. Drag and drop the Block file under load1 onto the Channels field of Subcase 1.
10. Repeat for the Block file under load2 and Subcase 2.
11. Activate the check box for Event_1.
12. Set LDM to 1.0, Scale to 3.0 and Offset to 0.0 for both subcases.

Figure 27:

13. Exit the dialog.

1.2.5 Evaluate and View Results

1. From the Evaluate tool group, click the Run Analysis tool.

Figure 28:

The Evaluate dialog opens.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.25

Figure 29:

2. Optional: Enter a name for the run.

3. Click Run.
Result files are saved to the home directory and the Run History dialog opens.

Figure 30:

4. Once the run is complete, click View Current Results.

5. Use the Results Explorer to visualize various types of results.

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.26

Figure 31:

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HyperLife Tutorials
1 Uniaxial Fatigue Analysis p.27

Figure 32:

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Multiaxial Fatigue Analysis 2
2 Multiaxial Fatigue Analysis

Multiaxial 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 HyperLife.

This chapter covers the following:

• 2.1 Stress-Life (S-N) Approach (p. 29)

• 2.2 Strain-Life (E-N) Approach (p. 38)
• 2.3 Factor of Safety (FOS) (p. 47)
HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.29

2.1 Stress-Life (S-N) Approach

In this tutorial you will:
• Import a model to HyperLife
• Select the SN module and define its required parameters
• Create and assign materials
• Assign load histories for scaling the stresses from FEA subcases
• Evaluate and view results

Prior to running through this tutorial, copy Models-h3d.zip from

<HyperWorks_installation_directory>\tutorials\hl to a local directory. Extract Ibeam.h3d,
load1.csv, and load2.csv from Models-h3d.zip..

2.1.1 Import the Model

1. From the Home tools, Files tool group, click the Open Model tool.

Figure 33:

2. From the Load model and result dialog, browse and select Ibeam.h3d for the model file.
The Load result field is automatically populated. For this tutorial, the same file is used for both the
model and the result.
3. Click Apply.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.30

Figure 34:

Tip: Quickly import the model by dragging and dropping the h3d file from a windows
browser into the HyperLife modeling window.

2.1.2 Define the Fatigue Module

1. From the Setup tools, click the SN tool.
The SN tool should be the default fatigue module selected. If it is not, click the arrow next to the
fatigue module icon to display a list of available options.

Figure 35:

The SN dialog opens.

2. Define the SN configuration parameters.
a) Select Multi Axial as the method.
b) Select MPA for the FE model units.
c) Enter a value of 0.5 for the certainty of survival.
d) Select GOODMAN for the Tension Damage Model.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.31

e) Select NONE for the Shear Damage Model.

f) Select Worst for the layer selection.

Figure 36:

3. Exit the dialog.

2.1.3 Assign Materials

1. From the Setup tools, click the Material tool.

Figure 37:

The Assign Material dialog opens.

2. Activate the checkboxes next to the parts Flange and Web.
3. Create a new material.
a) Click the My Material tab.
b) Click to create a new material.

c) Name the material Mat_SN_multiaxial.

d) Set the Elastic modulus to 200000.
e) Set the Input method to Slope-intcept,2-seg.
f) In the SN tab, set the Fatigue strength coefficient or Curve intercept (SR1) to 1203.
g) Set the Fatigue limit to 10.
h) Set the Standard error to 0.334.
i) Click the Other tab and ensure the Yield Strength is set to 250 and Poisson's Ratio is set to
0.333.
j) Accept all other default settings then click Plot & Save.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.32

Figure 38:

4. Right-click on Mat_SN_multiaxial and select Add to Assign Material List.

5. Return to the Assign Material Data tab and select Mat_SN_multiaxial from the Material drop-
down menu for both Flange and Web.
The Material list is populated with the materials selected from Material Database and My Material.

Figure 39:

6. Exit the dialog.

2.1.4 Assign Load Histories

1. From the Setup tools, click the Load Map tool.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.33

Figure 40:

The Load Map dialog opens.

2. From the Load Type drop-down menu, select Time Data.
3. Click and browse for load1.csv.
4. Click to add the load case.

5. Repeat steps 3 and 4 for load2.csv.

6. Optional: Click to view a plot of the loads.

Figure 41: Load 1

Figure 42: Load 2

Tip: Expand the width of the dialog to view a clearer picture of the plot.

7. On the bottom half of the dialog, set the radio button to Auto for event creation.
8. Select both the Block 1 channel under load1 and Subcase 1, then click to create the first event.
9. In a similar manner, create a second event by selecting Block 1 under load2 and Subcase 2.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.34

10. Activate the checkboxes for the two events.

11. Set the Scale to 8.0 for subcase 2.

Figure 43:

12. Exit the dialog.

2.1.5 Evaluate and View Results

1. From the Evaluate tool group, click the Run Analysis tool.

Figure 44:

The Evaluate dialog opens.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.35

Figure 45:

2. Optional: Enter a name for the run.

3. Click Run.
Result files are saved to the home directory and the Run History dialog opens.

Figure 46:

4. Once the run is complete, click View Current Results.

5. Use the Results Explorer to visualize various types of results.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.36

Figure 47:

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.37

Figure 48:

The life expectancy for the worst element is 64,660 cycles.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.38

2.2 Strain-Life (E-N) Approach

In this tutorial you will:

• Import a model to HyperLife
• Select the EN module and define its required parameters
• Create and assign materials
• Assign load histories for scaling the stresses from FEA subcases
• Evaluate and view results

Prior to running through this tutorial, copy Models-h3d.zip from

<HyperWorks_installation_directory>\tutorials\hl to a local directory. Extract Ibeam.h3d,
load1.csv, and load2.csv from Models-h3d.zip..

2.2.1 Import the Model

1. From the Home tools, Files tool group, click the Open Model tool.

Figure 49:

2. From the Load model and result dialog, browse and select Ibeam.h3d for the model file.
The Load result field is automatically populated. For this tutorial, the same file is used for both the
model and the result.
3. Click Apply.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.39

Figure 50:

Tip: Quickly import the model by dragging and dropping the h3d file from a windows
browser into the HyperLife modeling window.

2.2.2 Define the Fatigue Module

1. From the Setup tools, click the arrow next to the fatigue module icon and select the EN tool from
the list of options.

Figure 51:

The EN dialog opens.

2. Define the EN configuration parameters.
a) Select Multi Axial as the method.
b) Select MPA for the FE model units.
c) Enter a value of 0.5 for the certainty of survival.
d) Select SWT for the tension damage model.
e) Select FS for the shear damage model.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.40

f) Select Worst for the layer selection.

Figure 52:

3. Exit the dialog.

2.2.3 Assign Materials

1. From the Setup tools, click the Material tool.

Figure 53:

The Assign Material dialog opens.

2. Activate the checkboxes next to the parts Flange and Web.
3. Create a new material.
a) Click the My Material tab.
b) Click to create a new material.

c) Name the material Mat_EN_multiaxial.

d) Set the Elastic modulus to 70000.
e) In the SN tab, set the Standard error of Log(N) from elastic strain to 0.1.
f) In the SN tab, set the Standard error of Log(N) from plastic strain to 0.1.
g) Accept all other default settings, both in the EN and Other tabs, then click Plot & Save.

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2 Multiaxial Fatigue Analysis p.41

Figure 54:

4. Right-click on Mat_EN_multiaxial and select Add to Assign Material List.

5. Return to the Assign Material Data tab and select Mat_EN_multiaxial from the Material drop-
down menu for both Flange and Web.
The Material list is populated with the materials selected from Material Database and My Material.

Figure 55:

6. Exit the dialog.

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2.2.4 Assign Load Histories

1. From the Setup tools, click the Load Map tool.

Figure 56:

The Load Map dialog opens.

2. From the Load Type drop-down menu, select Time Data.
3. Click and browse for load1.csv.
4. Click to add the load case.

5. Repeat steps 3 and 4 for load2.csv.

6. Optional: Click to view a plot of the loads.

Figure 57: Load 1

Figure 58: Load 2

Tip: Expand the width of the dialog to view a clearer picture of the plot.

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7. On the bottom half of the dialog, set the radio button to Auto for event creation.
8. Select both the Block 1 channel under load1 and Subcase 1 then click to create the first
event.
9. In a similar manner, create a second event by selecting Block 1 under load2 and Subcase 2.
10. Activate the checkboxes for the two events.
11. Set the Scale to 3.0 for both subcases.

Figure 59:

12. Exit the dialog.

2.2.5 Evaluate and View Results

1. From the Evaluate tool group, click the Run Analysis tool.

Figure 60:

The Evaluate dialog opens.

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Figure 61:

2. Optional: Enter a name for the run.

3. Click Run.
Result files are saved to the home directory and the Run History dialog opens.

Figure 62:

4. Once the run is complete, click View Current Results.

5. Use the Results Explorer to visualize various types of results.

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Figure 63:

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Figure 64:

The life expectancy for the worst element is 33.92 cycles.

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HyperLife Tutorials
2 Multiaxial Fatigue Analysis p.47

2.3 Factor of Safety (FOS)

In this tutorial you will:

• Import a model to HyperLife
• Select the FOS module and define its required parameters
• Define material properties
• Assign load histories for scaling the stresses from FEA subcases
• Evaluate and view results

Prior to running through this tutorial, copy Models-h3d.zip from

<HyperWorks_installation_directory>\tutorials\hl to a local directory. Extract
Springlink_FOS.h3d and load1.csv from Models-h3d.zip..

2.3.1 Import the Model

1. From the Home tools, Files tool group, click the Open Model tool.

Figure 65:

2. From the Load model and result dialog, browse and select Springlink_FOS.h3d for the model
file.
The Load result field is automatically populated. For this tutorial, the same file is used for both the
model and the result.
3. Click Apply.

Figure 66:

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HyperLife Tutorials
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Tip: Quickly import the model by dragging and dropping the h3d file from a windows
browser into the HyperLife modeling window.

2.3.2 Define the Fatigue Module

1. From the Setup tools, click the arrow next to the fatigue module icon and select the FOS tool from
the list of options.

Figure 67:

The FOS dialog opens.

2. Accept the default parameters.

Figure 68:

3. Exit the dialog.

2.3.3 Define Material Properties

1. From the Setup tools, click the Material tool.

Figure 69:

The Assign Material dialog opens.

2. Activate the checkbox for the part spring_link_fine.

Note: The Material drop-down menu is greyed out and is not used in this calculation.

3. Click the TFL plot icon .

The TFL Table dialog opens.

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4. Define the torsional fatigue limit parameters.

a) Enter a value of 1000 for TFL.
b) Enter a value of 0.5 for HSS.
c) Enter a value of 0.0 for Shear Threshold.
d) Enter a value of 0.0 for Safe Zone Angle.

Figure 70:

5. Exit both dialogs.

2.3.4 Assign Load Histories

1. From the Setup tools, click the Load Map tool.

Figure 71:

The Load Map dialog opens.

2. From the Load Type menu, select Time Data.
3. Click and browse for load1.csv.
4. Click to add the load case.

5. Optional: Click to view a plot of the load.

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Figure 72: Load 1

Tip: Expand the width of the dialog to view a clearer picture of the plot.

6. On the bottom half of the dialog, set the radio button to Manual for event creation and click

three times to create three event headers.

7. Drag and drop Subcase 1 under Event_1, Subcase 2 under Event_2, and Subcase 3 under
Event_3.
8. Drag and drop the Block file under load1 onto the Channels field of all three subcases.
9. Activate the check boxes for the three events.
10. Set LDM to 1.0, Scale to 3.0 and Offset to 0.0 for Subcase 1.
11. Right-click on the Scale field of Subcase 1 and select Apply value to all events.

Figure 73:

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12. Exit the dialog.

2.3.5 Evaluate and View Results

1. From the Evaluate tool group, click the Run Analysis tool.

Figure 74:

The Evaluate dialog opens.

Figure 75:

2. Optional: Enter a name for the run.

3. Click Run.
Result files are saved to the home directory and the Run History dialog opens.

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Figure 76:

4. Once the run is complete, click View Current Results.

5. Use the Results Explorer to visualize various types of results.

Figure 77:

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Weld Fatigue Analysis 3
3 Weld Fatigue Analysis

Perform seam and spot weld fatigue analysis using HyperLife.

This chapter covers the following:

• 3.1 Spot Weld (CBAR) (p. 54)

• 3.2 Seam Weld (Fillet) (p. 63)
HyperLife Tutorials
3 Weld Fatigue Analysis p.54

3.1 Spot Weld (CBAR)

In this tutorial you will:

• Import a model to HyperLife
• Select the Weld module and define its required parameters
• Create and assign materials to the welds and sheet groups
• Assign load histories for scaling the stresses from FEA subcases
• Evaluate and view results

Prior to running through this tutorial, copy Models-h3d.zip from

<HyperWorks_installation_directory>\tutorials\hl to a local directory. Extract
Rail_SpotWeld.h3d and Rail_SpotWeld.force from Models-h3d.zip..

3.1.1 Import the Model

ELFORCES are required for this analysis.

1. From the Home tools, Files tool group, click Open Model.

Figure 78:

2. From the Load model and result dialog, browse and select Rail_SpotWeld.h3d for the model
file.
The Load result field is automatically populated. For this tutorial, the same file is used for both the
model and the result.

Note: The .h3d file should contain the following result types for this calculation:
• CBAR/CBEAM Axial Force A
• CBAR/CBEAM Shear Plane - 1A
• CBAR/CBEAM Shear Plane - 2A
• CBAR/CBEAM Torque A
• CBAR/CBEAM Bending Plane - 1A
• CBAR/CBEAM Bending Plane - 2A
• CBAR/CBEAM Bending Plane - 1B
• CBAR/CBEAM Bending Plane - 2B

3. Click Apply.

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Figure 79:

The spot welds are modelled with CBAR elements between the two plates.

Figure 80:

Tip: Quickly import the model by dragging and dropping the h3d file from a windows
browser into the HyperLife modeling window.

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3.1.2 Define the Fatigue Module

1. From the Setup tools, click the arrow next to the fatigue module icon and select the Weld tool
from the list of options.

Figure 81:

The Weld dialog opens.

2. Accept the default parameters.

Figure 82:

3. Exit the dialog.

3.1.3 Assign Materials

1. From the Setup tools, click the Material tool.

Figure 83:

The Assign Material dialog opens.

2. Activate the checkboxes for the Grp_1 and Grp_2 sheet groups.
3. Click the My Material tab.
4. Click .
A new material named Mat_WELD("n") is created.
5. Select Estimate from UTS as the input method.
6. Select Steel as the type and enter a value of 1200 for UTS.
7. Click Estimate to obtain SN parameters.

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8. Enter a value of 1.0 for the standard error.

Figure 84:

9. Click Plot & Save.

10. Right-click on Mat_Weld("n") and select Add to Assign Material List.
11. Return to the Assign Material Data tab.
12. Select Mat_Weld("n") from the Material drop-down menu for every part.
13. For both groups, enter a value of 2.0 for the Thickness/Diameter of Sheet 2.
14. For both groups, enter a value of 8.0 for the Thickness/Diameter of Nugget.

Figure 85:

15. Exit the dialog.

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3.1.4 Assign Load Histories

1. From the Setup tools, click the Load Map tool.

Figure 86:

The Load Map dialog opens.

2. From the Load Type menu, select Constant Amplitude.
3. Click to add the load case.

Tip: Click to view a plot of the load.

Figure 87:

4. On the bottom half of the dialog, set the radio button to Auto for event creation and select Single
Event from the drop-down menu.
This option assists in automatically creating an event based on the subcase and channel selection.
5. Select both Subcase 1 and ConsAmpEvent1 and click next to Single Event.
An Event_1 header is created.
6. Select Subcase 2 and ConsAmpEvent1 and click .
An Event_2 header is created.
7. In a similar manner, create an Event_3 header.
8. Activate the check boxes for all three events.
9. Set LDM to 1.0, Scale to 8.0 and Offset to 0.0 for Subcase 1.
10. Right click on the Scale field for Subcase 1 and select Apply value to all events.

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Figure 88:

11. Exit the dialog.

3.1.5 Evaluate and View Results

1. From the Evaluate tool group, click the Run Analysis tool.

Figure 89:

The Evaluate dialog opens.

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Figure 90:

2. Optional: Enter a name for the run.

3. Click Run.
Result files are saved to the home directory and the Run History dialog opens.

Figure 91:

4. Once the run is complete, click View Current Results.

5. Use the Results Explorer to visualize various types of results.

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Figure 92:

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3 Weld Fatigue Analysis p.62

Figure 93:

The life of the critical spot weld is around 6.212e09 cycles.

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HyperLife Tutorials
3 Weld Fatigue Analysis p.63

3.2 Seam Weld (Fillet)

In this tutorial you will:

• Import a model to HyperLife
• Select the Weld module and define its required parameters
• Create and assign materials to the welds and sheet groups
• Assign load histories for scaling the stresses from FEA subcases
• Evaluate and view results

Prior to running through this tutorial, copy Models-h3d.zip from

<HyperWorks_installation_directory>\tutorials\hl to a local directory. Extract Seam-Fillet.h3d,
Seam-Fillet.gpf, load1.csv, and load2.csv from Models-h3d.zip..

3.2.1 Import the Model

1. From the Home tools, Files tool group, click the Open Model tool.

Figure 94:

2. From the Load model and result dialog, browse and select Seam-Fillet.h3d for the model file.
The Load result field is automatically populated. For this tutorial, the same file is used for both the
model and the result.

Note: Seam weld analysis is performed using grid point forces, which can be made
available with *.gpf files in the model directory. If no *.gpf file is present, the grid
point forces should be included in the .h3d file.

3. Click Apply.

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Figure 95:

Tip: Quickly import the model by dragging and dropping the h3d file from a windows
browser into the HyperLife modeling window.

3.2.2 Define the Fatigue Module

1. From the Setup tools, click the arrow next to the fatigue module icon and select the Weld tool
from the list of options.

Figure 96:

The Weld dialog opens.

2. Set the type to Seam.
3. Set the certainty of survival to 0.6.
4. Accept all other default parameters.

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Figure 97:

5. Exit the dialog.

3.2.3 Assign Materials

1. From the Setup tools, click the Material tool.

Figure 98:

The Assign Material dialog opens.

2. Using the drop-down menu at the top, left of the dialog, change the components from Sets to
Parts.
3. In the Select Weld Parts window, activate the checkbox next to auto2.
4. Click Find Weld Toe, Root.
The adjacent attached components are displayed.
5. Create a bending material.
a) Click the My Material tab.
b) Click to create a new material.

c) Name the material Mat_WELD_bending.

d) Change the Input method to Slope-intcept,2-seg.
e) In the SN tab, set the Fatigue strength coefficient or Curve intercept (SR1) to 1203.
f) Set the Fatigue limit to 100.
g) Set the Standard error value to 0.334.
h) Click the Other tab and ensure the Yield Strength is set to 250 and Poisson's Ratio is set to
0.333.
i) Accept all other default settings then click Plot & Save.

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Figure 99:

6. Create a membrane material.

a) Staying in the My Material tab, click to create another material.

b) Name the material Mat_WELD_membrane.

c) Change the Input method to Slope-intcept,2-seg.
d) In the SN tab, set the Fatigue strength coefficient or Curve intercept (SR1) to 803.000.
e) Set the First fatigue strength exponent or Slope (B1) to -0.150.
f) Set the Second fatigue strength exponent to -0.110.
g) Set the Fatigue limit to 100.
h) Set the Standard error value to 0.334.
i) Click the Other tab and ensure the Yield Strength is set to 250 and Poisson's Ratio is set to
0.333.
j) Accept all other default settings then click Plot & Save.

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Figure 100:

7. Right-click on both Mat_WELD_bending and Mat_WELD_membrane and select Add to

Assign Material List.
8. Return to the Assign Material tab.
9. Set Mat_WELD_bending as Material (B) and Mat_WELD_membrane as Material (M) for both
components.
The Material list is populated with the materials selected from Material Database and My Material.

Note: The Material Database contains default bending and membrane materials for
seam weld analyses.

10. Set BRATIO to 0.6 for both components.

11. Set TREF_N to 0.1 for both components.

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Figure 101:

12. Exit the dialog.

3.2.4 Assign Load Histories

1. From the Setup tools, click the Load Map tool.

Figure 102:

The Load Map dialog opens.

2. From the Load Type drop-down menu, select Time Data.
3. Click and browse for load1.csv.
4. Click to add the load case.

5. Repeat steps 3 and 4 for load2.csv.

6. Optional: Click to view a plot of the loads.

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Figure 103: Load 1

Figure 104: Load 2

Tip: Expand the width of the dialog to view a clearer picture of the plot.

7. On the bottom half of the dialog, set the radio button to Auto for event creation.
8. Select both the Block 1 channel under load1 and Subcase 1, then click to create the first
event.
9. Next, select both Block 1 channels, Subcase 2, and Subcase 3 then click .
A second event is created.

Tip: Hold Control while left-clicking to select multiple options.

10. Activate the checkboxes for the two events.

11. Set the LDM to 0.5 for Subcase 1.
12. Right-click on the LDM field and select Apply value to all events.
Subcases 2 and 3 inherit the LDM value.
13. Similarly, set the Scale to 0.6 for all three subcases.

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Figure 105:

14. Exit the dialog.

3.2.5 Evaluate and View Results

1. From the Evaluate tool group, click the Run Analysis tool.

Figure 106:

The Evaluate dialog opens.

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Figure 107:

2. Optional: Enter a name for the run.

3. Click Run.
Result files are saved to the home directory and the Run History dialog opens.

Figure 108:

4. Once the run is complete, click View Current Results.

5. Use the Results Explorer to visualize various types of results.

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Figure 109:

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Figure 110:

The life expectancy for the worst element is 5.484e4 cycles.

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Transient Fatigue Analysis 4
4 Transient Fatigue Analysis

Perform transient fatigue analysis using a S-N (stress-life) approach in HyperLife.

This chapter covers the following:

• 4.1 Stress-Life (S-N) Approach (p. 75)

HyperLife Tutorials
4 Transient Fatigue Analysis p.75

4.1 Stress-Life (S-N) Approach

During Transient Fatigue Analysis, the load-time history input is not required, as it is calculated
internally during transient analysis.

This example will detail a Stress-Life fatigue calculation for a transient subcase. Transient Fatigue
Analysis is currently supported for SN (uniaxial and multiaxial) and EN (uniaxial and multiaxial)

In this tutorial you will:

• Import a model to HyperLife
• Select the SN module and define its required parameters
• Create and assign materials
• Create an event
• Evaluate and view results

Prior to running through this tutorial, copy Models-h3d.zip from

<HyperWorks_installation_directory>\tutorials\hl to a local directory. Extract Bracket-SN-
Transient.h3d from Models-h3d.zip..

4.1.1 Import the Model

1. From the Home tools, Files tool group, click the Open Model tool.

Figure 111:

2. From the Load model and result dialog, browse and select Bracket-SN-Transient.h3d for the
model file.
The Load result field is automatically populated. For this tutorial, the same file is used for both the
model and the result.
3. Click Apply.

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Figure 112:

Tip: Quickly import the model by dragging and dropping the h3d file from a windows
browser into the HyperLife modeling window.

4.1.2 Define the Fatigue Module

1. From the Setup tools, click the SN tool.
The SN tool should be the default fatigue module selected. If it is not, click the arrow next to the
fatigue module icon to display a list of available options.

Figure 113:

The SN dialog opens.

2. Define the SN configuration parameters.

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a) Select Uni Axial as the method.

b) Select MPA for the FE model units.
c) Select Signed von for the stress combination.
d) Enter a value of 0.6 for the certainty of survival.
e) Select GOODMAN for the mean stress connection.
f) Select Worst for the layer selection.

Figure 114:

3. Exit the dialog.

4.1.3 Assign Materials

1. From the Setup tool group, click the Material tool.

Figure 115:

The Assign Material dialog opens.

2. Activate the checkbox next to new_bracket.
3. Create a new material.
a) Click the My Material tab.
b) Click to create a new material.

c) Set the Elastic modulus to 200000.

d) Change the Input method to Slope-intcept,2-seg.
e) Set UTS to 2000.
f) In the SN tab, set the Fatigue strength coefficient or Curve intercept (SR1) to 1040.
g) Set the First fatigue strength exponent or Slope (B1) to -0.231.
h) Set the Cyclic limit of endurance or Transition point (NC1) to 600000.
i) Set the Second fatigue strength exponent (B2) to -0.110.
j) Set the Fatigue limit to 10.

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k) Set the Standard error value to 0.01.

l) Click the Other tab and set Yield Strength to 1800.
m) Click Plot & Save.

Figure 116:

4. Right-click on Mat_SN("n") and select Add to Assign Material List.

5. Return to the Assign Material tab and select Mat_SN("n") from the Material drop-down menu
for new_bracket.
The Material list is populated with the materials selected from Material Database and My Material.
6. Set Finish to POLISH, Surf Treatment to NITRIDED, and Kf to 1.3.

Figure 117:

7. Exit the dialog.

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4.1.4 Assign Load Histories

1. From the Setup tool group, click the Load Map tool.

Figure 118:

The Load Map dialog opens.

2. From the Load Type menu, select Transient Response.
Since this is a transient fatigue analysis, a load history is not required.
3. Select Subcase 1 (transient).
4. On the bottom half of the dialog, set the radio button to Auto for event creation and click to
create an Event_1 header.
Subcase 1 is listed under the event.
5. Activate the Event_1 checkbox.

Figure 119:

6. Exit the dialog.

4.1.5 Evaluate and View Results

1. From the Evaluate tool group, click the Run Analysis tool.

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Figure 120:

The Evaluate dialog opens.

Figure 121:

2. Optional: Enter a name for the run.

3. Click Run.
Result files are saved to the home directory and the Run History dialog opens.

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Figure 122:

4. Once the run is complete, click View Current Results.

5. Use the Results Explorer to visualize various types of results.

Figure 123:

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Figure 124:

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Index
F
factor of safety tutorial 47

M
multiaxial fatigue analysis 28

S
seam weld fillet tutorial 63
spot weld cbar tutorial 54
strain-life approach multiaxial tutorial 38
strain-life approach uniaxial tutorial 19
stress-life approach multiaxial tutorial 29
stress-life approach tutorial 9, 75

T
tutorial, factor of safety 47
tutorial, seam weld fillet 63
tutorial, spot weld cbar 54
tutorial, strain-life approach multiaxial 38
tutorial, strain-life approach uniaxial 19
tutorial, stress-life approach 9, 75
tutorial, stress-life approach multiaxial 29

U
uniaxial fatigue analysis 8

83