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FE-SAFE OVERVIEW


DURABILITY ANALYSIS SOFTWARE FOR FINITE ELEMENT MODELS

 * Contact sales



Industry is putting increasing pressure on manufacturers to use less material to
deliver lightweight but stronger components, lower warranty and recall costs and
all in less time. Many companies use advanced finite element analysis to
calculate design stresses, but the fatigue analysis is often still done by
manually picking stress points for spreadsheet analysis. This is time-consuming
and unreliable because it is easy to miss failure locations.
The fe-safe suite of software is world-leading technology for durability
analysis from FEA, directly interfacing to all major FEA suites (Abaqus, ANSYS,
Nastran (MSC, NEi, NX), Pro/Mechanica) and its capabilities have been developed
to meet the most demanding industry applications.
fe-safe was the first commercially available fatigue analysis software to focus
on modern multiaxial strain-based fatigue methods and it continues to set the
benchmark for fatigue analysis software.


fe-safe is included in Extended Packaging, allowing unified access to all
solution technologies within the portfolio through a single token pool.

 

The fe-safe suite provides:

 * fe-safe: Accurate, reliable multiaxial fatigue analysis, regardless of the
   complexity of your loadings and model
 * fe-safe/Rubber: Unique, leading-edge technology for the fatigue analysis of
   elastomers
 * Verity Module in fe-safe: The original, patented Verity™ Structural Stress
   Method for seam, structural and spot welded joints
 * fe-safe/TURBOlife: Thermomechanical fatigue analysis with unique capabilities
   for creep-fatigue interaction
 * Smooth workflow between the SIMULIA portfolio of products: Abaqus, Isight and
   Tosca


Regardless of the complexity of your fatigue analysis, fe-safe fits smoothly
into your design process, enabling you to develop products that are designed for
durability.

[click to enlarge image]

FATIGUE ANALYSIS OF A SUSPENSION COMPONENT

"fe-safe correctly predicted the failure location due to high, low and combined
level loading. The analysis took residual stress, material non-linearity and
plastics strains into account."
Hyundai Motor Company



[click to enlarge image]

COMPARISON OF FE-SAFE AND THE 'S-N + HAIGH' METHOD ON A CYLINDER HEAD



 * 1. Traditional approach using SN Curves and Goodman diagrams missed the
   correct site and identified false crack initiation sites
 * 2. fe-safe accurately identified the correct crack initiation sites

Cummins Inc.





 * Benefits
 * Key Questions

Benefits

With the fe-safe product suite as an integrated part of your design process, you
have the ability to:

 

 * Increase the fatigue life of safety critical components
 * Optimize designs to use less material
 * Reduce product recalls and warranty costs
 * Optimize and validate design and test programs
 * Improve correlation between test and analysis within a single user interface
 * Reduce prototype test times
 * Speed up analysis times, thereby reducing man-time hours
 * Increase confidence that product designs pass physical test schedules as
   "right-first-time"
 * Reduce reliance on physical testing

Key Questions


WHY SHOULD I USE FATIGUE ANALYSIS SOFTWARE?

Fatigue failures are costly and can result in accidents - or at least, expensive
product recalls and warranty claims. Traditional fatigue analysis methods are
time-consuming and unreliable and test programs can be lengthy and open-ended.


IS ALL FATIGUE SOFTWARE THE SAME?

No. Not all fatigue analysis software is as accurate as fe-safe. And getting the
wrong result is arguably worse than not doing a fatigue analysis at all.
Re-designing a component on the back of an incorrect analysis result is costly
and time-consuming and does not lead to production of the lightest and most
durable product. fe-safe gives fast, accurate results regardless of the
complexity of the analysis. It does this by using advanced multiaxial
strain-based fatigue methods. Users consistently report excellent correlation
with test results.



IS FE-SAFE RIGHT FOR MY INDUSTRY?

Yes - providing you conduct finite element analysis using one of the main FEA
packages and you are concerned with the durability of products or components
made from metal or elastomers. fe-safe includes a comprehensive materials
database and handles weld fatigue - including spot welds - vibration, high
temperature and creep fatigue.


DO I HAVE TO CHOOSE BETWEEN SPEED AND ACCURACY?

No. Unique nodal elimination methods in fe-safe ensure that there is no
trade-off between getting your result quickly and getting the correct result -
regardless of the complexity of the analysis. Users consistently report
excellent correlation with test results.


DO I NEED TO BE A FATIGUE EXPERT?

No, you can leave that to us. There are factors which cannot be ignored if
results are to be trusted. However, because fe-safe is technically advanced, it
is configured to take into account many variables which will affect the accuracy
of your results automatically.


CAN I GET FAST, ACCURATE RESULTS FOR MY SIMPLE ANALYSES?

Yes. fe-safe is not just for the complex stuff. However, even a simple analysis
may not be as straightforward as you have been led to believe. As fatigue
experts, we know that there are variables which cannot be disregarded if you
want a truly accurate result. Because fe-safe is technically advanced and
designed by fatigue experts, it automatically takes into account important
factors that can still make a dramatic difference to the accuracy of your
results. The results from your 'simple' analysis are fast and accurate.


CAN I GET FAST, ACCURATE RESULTS FOR MY COMPLEX ANALYSES?

Yes. Highly efficient and advanced coding plus parallel and distributed
processing allow fe-safe to analyze large finite element models accurately and
report results quickly. Assemblies of different parts, surface finishes and
materials can be analyzed in a single run and fe-safe automatically changes the
method of analysis as it moves from one material to another so you are always
using the most appropriate algorithm. Also, fe-safe is highly configurable for
the advanced user.


ARE THESE THE CORRECT FATIGUE 'HOT SPOTS'?

If these are not identified correctly, you end up adding material in the wrong
places, which results in a heavier component that still isn't designed for
optimum durability! Advanced, multiaxial algorithms are the core of fe-safe and
are backed up by sound fatigue theory. fe-safe shows how much the design is
over-strength or under-strength at each node, giving you the confidence that you
are adding material only where necessary to achieve optimum fatigue life.


WHAT IS THE FATIGUE LIFE OF THIS COMPONENT?

Knowing when a part will break due to fatigue failure is invaluable information
when it comes to managing test and maintenance programs. With fe-safe as part of
your design and analysis workflow, you will see excellent correlation between
your test and analysis results - within a single user interface. This in turn
reduces prototype test times and gives you the confidence that your product
designs will pass their test schedules as "right first time".

fe-safe uses advanced critical plane multiaxial fatigue with in-built plasticity
modeling to post-process results from an elastic FEA. Results can be displayed
as contour plots showing crack locations and fatigue lives.


WHAT IS CAUSING FATIGUE CRACKING?

fe-safe can provide detailed results for hot-spot areas or individual elements
or nodes, time histories of calculated stresses and strains, fatigue cycle and
damage histograms, Haigh and Smith plots and many other graphs in order to
explain why the fatigue life is what it is.


WILL THE CRACKS PROPAGATE?

fe-safe uses critical distance methods to check whether cracks will propagate.
Allowing cracks to initiate but not propagate to failure may allow higher
working stresses and lighter, more efficient designs.


WHERE CAN MATERIAL BE SAVED? WHERE MUST EXTRA MATERIAL BE ADDED?

fe-safe calculates the allowable stresses or loads to achieve a specified
service life. This is the factor of strength (FOS). fe-safe fully accounts for
any changes in plasticity that may be caused by changes to loads or stresses.
fe-safe shows how much the design is over-strength or understrength at each
node. Results are displayed as contour plots.


HOW RELIABLE IS THIS DESIGN?

The 'warranty claim' calculation combines variability in material strength and
variability in loading to estimate the proportion of components un-cracked after
any period of time in service. This can be used to achieve uniform reliability
over different parts of an assembly. Factor of Strength (FOS) and Probability of
Survival calculations can be combined with the initial fatigue life calculation
in a single run. Together they show the interaction between design stress
margins and component reliability.


WHICH LOADS ARE CAUSING FATIGUE DAMAGE?

fe-safe performs a load sensitivity analysis to show the effect of each applied
load. This can be used to refine the design, and to design and validate an
accelerated fatigue test. Once the critical and non-critical loads have been
identified, test programs can be optimized and validated by removing
unrepresentative tests.


PRODUCT SUITE

 * fe-safe
 * fe-safe/Rubber
 * fe-safe/TURBOlife
 * safe4fatigue
 * Verity in fe-safe

 

 





MORE INFORMATION

 * fe-safe Brochure
 * fe-safe/Rubber Brochure
 * fe-safe/TURBOlife Brochure
 * Verity Module in fe-safe Brochure
 * fe-safe Industry Applications





LATEST RELEASE E-SEMINAR


REGISTER NOW

Learn about new features in fe-safe and Tosca R2021x



 * USA & Canada:                         1855 696 1125
   India:                                       +91 800 040 45 74
   Other English countries: +800 379 78 361
   CONTACT US FOR SALES (free of charge from landlines)
   
 * Contact sales





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