Contents

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Fatigue Module Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Analysis

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Cumulative Damage Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Elastic-Plastic Formulation Definitions . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Analysis Procedure for Cyclic Loading . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Procedure (at a Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-Nodes Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simplified Elastic-Plastic Formulation . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2-5 2-6 2-7

Description of Elements

. . . . . . . . . . . . . . . . . . . . . . . . 3-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

In de x

COSMOSM Advanced Modules

Contents

Brief Description of Commands

. . . . . . . . . . . . . . . . . . .4-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Commands Likely to be Used for a Given Analysis . . . . . . . . . . . . . . . . .4-1 Analysis Menu (Analysis > FATIGUE) . . . . . . . . . . . . . . . . . . . . . . . .4-2 Analysis Menu (Analysis > FATIGUE > FATIGUE LIST) . . . . . . . . .4-2 Analysis Menu (Analysis > FATIGUE > FATIGUE DELETION) . . .4-3 Results Menu (Results > PLOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Detailed Description of Examples

. . . . . . . . . . . . . . . . . .5-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 How FSTAR Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Cylinder Under Axial Cyclic Loading Example . . . . . . . . . . . . . . . . . . . .5-4 History Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Starting The Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Specifying the Fatigue Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Defining the Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Defining a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Specifying the Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Specifying the Fatigue Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Running the Fatigue Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 Interpretation of the Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 Fatigue Caused by Pressure Loading Example . . . . . . . . . . . . . . . . . . . .5-12 Structural Modeling and Stress Analysis . . . . . . . . . . . . . . . . . . . . . . .5-13 Fatigue Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 Fatigue Analysis (All-Nodes Option) . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 Fatigue Caused by Thermal Loading Example . . . . . . . . . . . . . . . . . . . .5-17 Creating the Model Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 Specifying and Running the Thermal Analysis . . . . . . . . . . . . . . . . . .5-19 Specifying and Running the Stress Analysis . . . . . . . . . . . . . . . . . . . .5-20 Specifying and Running the Fatigue Analysis . . . . . . . . . . . . . . . . . . .5-20 Running the Analysis Based on the Elastic-Plastic Formulation . . . . .5-21

In de x

ii

COSMOSM Advanced Modules

Contents FSTAR / Fatigue Analysis

A Brief Theoretical Background for Simplified Elastic-Plastic Formulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Section Orientation in Junctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Stress Linearization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Cartesian Formulation (Approximation) . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Axisymmetric Formulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Simplified Elastic-Plastic Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

In de x

COSMOSM Advanced Modules

iii

Contents

In de x

iv

COSMOSM Advanced Modules

Introduction

Introduction
The suitability of a mechanical or structural component for specific service involving cyclic application of loads and thermal conditions is determined by the use of the fatigue module. The basic postulate adopted for fatigue calculations with spectrum loading is the cumulative damage theory based on the Miners rule.

Fatigue Module Capabilities

The Fatigue module, FSTAR, provides engineers with the capability to perform fatigue analysis of their structural designs using the data base created with the stress module of COSMOSM. Analysis can be performed easily and quickly to determine the predicted life of a design and identify areas that are fatigue critical. FSTAR calculates fatigue usage factor (fraction of life used up by a combination of fatigue events) for any point of a structural model. The model can consist of 1D, 2D plane and axisymmetric, 3D solid and shell elements. Stress conditions at any point can be due to mechanical loadings and/or thermal loadings. All events and the corresponding number of cycles are defined easily by the user. At each location being evaluated, the stress can be associated with load conditions previously calculated with COSMOSM (load cases/time-steps), or it can be directly input by the user. The user has also the flexibility to modify the stored stresses in the data

In de x

COSMOSM Advanced Modules

1-1

Chapter 1 Introduction

base. The solution is based on the Miners rule approach and the ASME Boiler and Pressure Vessel Code. There is also a capability to evaluate the fatigue usage factor using the ASME Code for a simplified elastic-plastic formulation. The powerful graphics capability of the COSMOSM software can be utilized to display color plots of fatigue life and to identify the fatigue critical regions.

In de x

1-2

COSMOSM Advanced Modules

Analysis

Introduction
This chapter covers background information, definitions and the procedure for conducting a fatigue analysis.

Cumulative Damage Theory

Service operation at any given cyclic stress amplitude produces fatigue damage, the seriousness of which will be related to the total number of cycles that would be required to produce failure of an undamaged component at that stress amplitude. It is also assumed that the damage incurred is permanent. The method adopted here is a cumulative damage method based on the Miners rule. To have a better understanding of the general theory, first consider the following example: Assume that operation at several different stress amplitudes S1, S2,..., St in sequence for a number of cycles n1, n2,..., nt will result in an accumulation of total damage equal to the sum of the damage increments accrued at each individual stress level. Then if operation at a stress amplitude (level) S1 produces complete damage (or failure) in N1 cycles, operation at stress amplitude S1 (event 1) for a

In de x

COSMOSM Advanced Modules

2-1

Chapter 2 Analysis

number of cycles n1 smaller than N1 will produce a smaller fraction of damage, say D1. Factor D1 is termed damage fraction (usage factor). Operation over a spectrum of different stress levels results in a usage factor Di for each of the different stress levels Si in the spectrum (in the following development each one of the different load level operations, which may consist of a number of cycles, is called an event). When these factors sum to unity, failure is predicted; that is, (2-1) The linear damage rule states that the damage fraction (usage factor), Di, at stress level Si is equal to the cycle ratio ni/Ni. Thus, the damage fraction D due to one cycle of loading is 1/N. In other words, the application of one cycle of loading consumes 1/N of the fatigue life. The failure criterion for variable amplitude loading can now be stated as (2-2) In the above postulate it is assumed that there is no interaction between different events, i.e. each event (consisting of a number of cycles of the same load level) occurs in complete isolation from the other events. However, in practical applications, every load cycle of the spectrum may contain multiple load levels. The fatigue analysis of FSTAR also includes this latter effect as will be described in more details in the section on Analysis Procedure for Cyclic Loading.

Definitions
General Definitions Loading History
A series of load steps which may occur for a number of times.

Event
A portion of loading history which has a frequency of occurrence.
In de x

2-2

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

Fatigue Loading
A specified point in the loading history such as where the stress level is at the extreme.

Location
A point on the structure for which the fatigue calculation is to be performed.

Stress Condition
Corresponds to the state of stress at a location for a particular (fatigue) loading.

Loading Combination (Set)

Is the combination of two loadings. There are as many as N(N-1)/2 loading combinations, where N is the number of loadings.

Component Stress Range

Is computed for a loading combination, when the six components of stress field at one (stress) condition are subtracted from the six components at the other condition.

Alternating Stress (Intensity)

If C1, C2 and C3 are the three principal stresses obtained from the component stress range and S12 = C1 - C2, S23 = C2 - C3 and S31 = C3 - C1 are the three stress differences, then the alternating stress intensity (Salt) is one-half of the largest absolute magnitude of any stress difference.

Alternating Stress Intensity List

A list of all possible combinations of alternating stress intensities (at a location) in decreasing order.

Partial Usage Factor

For loading combination i, the partial usage factor is equal to the cycle ratio ni/Ni, where ni is the lower number of cycles remaining from either events E or F. Events E and F contain the two loadings which constitute loading combination i, and Ni is the allowable number of cycles interpolated from the S-N curve for the alternating stress intensity Salti (resulted from loading combination i).
In de x

COSMOSM Advanced Modules

2-3

Chapter 2 Analysis

Cumulative Usage Factor

Sum of all partial usage factors.

Processing Phase
Initial COSMOSM finite element structural results (from STAR, HSTAR, ASTAR, or NSTAR modules) applicable as input to the fatigue calculations.

Load Case (Time Step)

Stresses stored in the database during the processing phase. These stresses are considered in fatigue calculations once a load case (time step) is associated with a (fatigue) loading.

Scale Factor
Is a stress multiplier. It applies to stresses which are read for a fatigue loading from the database stress file. The database stress file contains the finite element structural solution obtained during the Processing Phase.

Stress Concentration Factor (in X, Y and Z directions)

Applies to the normal stress components at a specified location. This factor is to be used more as a measure of the mesh refinement in the model used for finite element analysis, in the areas where fatigue calculation is being performed. If the model is fine enough, it takes a value of one in all directions. It may be increased to higher values depending on the coarseness of the finite element mesh. This factor may also be used to account for the existence of any local stress concentration effects other than geometry effects.

Elastic-Plastic Formulation Definitions Section

A straight path through the wall (in the thickness direction) of an axisymmetric structure.

Linearized Stress
The equivalent linear stress distribution along a section which has the same net bending moment as the actual distribution.
In de x

2-4

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

Membrane Stress
The constant portion of stress such that pure moment acts on a section plane after the membrane is subtracted from the equivalent linearized stress.

Bending Stress:
The variable portion of stress equal to the equivalent linear stress minus the membrane stress.

Design Stress
The allowable design stress intensity value (Sm) at a particular temperature as specified by the Sm-T curve. (These curves may be found in tables I-2.1 and I-2.2 of Reference 5).

Sm-T Curve
Design stress versus temperature.

Analysis Procedure for Cyclic Loading

Normal Procedure (at a Location)
1.

When a design fatigue curve (S-N curve) is not defined, the program evaluates the alternating stress intensities according to the ASME Boiler and Pressure Vessel Code [Reference 1]. Alternating stress intensities are evaluated between all possible pairs of loading combinations. That is, for a defined location, all six stress components of loading A will be subtracted from the corresponding components of loading B to yield component stress range from which the alternating stress intensities are evaluated according to the General Definitions section. These alternating stress intensities are listed for all possible combinations in decreasing order together with their corresponding loading pairs. No usage factor is evaluated in this case. When a design fatigue curve (S-N curve) is defined, the program checks the alternating stress intensity list from the top (highest value) to the bottom (lowest value). It evaluates the partial usage factor Di for the ith alternating stress intensity in that list by evaluating the cycle ratio ni/Ni (as its equivalence). The ith alternating stress intensity is formed by the combination of loadings AE and

2.

In de x

COSMOSM Advanced Modules

2-5

Chapter 2 Analysis

BF, where E and F are the corresponding events. Here, ni corresponds to the lower number of cycles remaining from either events E and F, and Ni corresponds to the allowable number of cycles interpolated from the design fatigue curve (SN curve). After evaluating the partial usage factor Di, the program updates the alternating stress intensity list by reducing the number of cycles of both events E and F by ni. Consequently, one of the two events E or F will be eliminated (or both if E and F have the same number of cycles) and the other event will have ni cycles less in the later calculations. Elimination of an event results in elimination of the corresponding loadings. Once a loading is eliminated the corresponding stress intensities (formed by combination of that loading with other loadings) will also be eliminated from the list. After updating the list the program checks the next alternating stress intensity in the list and evaluates the corresponding partial usage factor, adds that to the cumulative one and updates the list. This procedure will be repeated for the next alternating stress intensity in the list and continues until all stress intensities are considered.
3.

An S-N curve is defined by log-log interpolation between the points (on the curve) and linear interpolation among all the (S-N) curves with different stress ratios if more than one curve is defined by the user. Also available are two predefined (optional) curves for Carbon or Austenitic Steels which the user may consider instead. For any alternating stress within the stress range S1 and S2 (the first and last points) of an S-N curve the program uses log-log interpolation to find the corresponding cycle. For any stress larger (smaller) than S1 (S2), the program assigns N1 (N2) as the corresponding number of cycles, where N1 and N2 correspond to the first and last points of the curve. Therefore, it is important that the user defines the S-N curve for a wide range of cycles. For the same reason, if an endurance limit is to be implemented into the curve, it is appropriate to have a relatively large number of cycles assigned to the last point (N2) on the curve.

All-Nodes Option
This option is similar to the normal procedure except that the fatigue calculation is performed for a structure at all nodes. The program has the following limitations:
1.

In de x

Since the calculation is done on the nodal basis, no location has to be defined (all defined locations will be ignored).

2-6

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis 2. 3.

All defined concentration factors will be ignored. All stresses are read either from stress files created during the processing phase or considered to be zero if they are so defined (using command FT_LOAD (Analysis > FATIGUE > Fatigue Load). No modification on the nodal stresses are allowed (i.e., any assignment made by the command FT_STREAD (Analysis > FATIGUE > Apply Stress) is ignored). No elastic-plastic formulation will be incorporated into the calculation at any node.

4.

Simplified Elastic-Plastic Formulation

If a simplified elastic-plastic formulation is desired, the following steps must be taken:
1.

For an axisymmetric structure Figure 2-1. Two Types of Sections Defined such as a pressure vessel and a by Locations at Their Two Ends fatigue critical location (on the inner or outer surface), define a C L thickness-through section with one end at the desired location (Figure 2-1). The section must present a rational plane of 1 2 bending which, in most cases, will be perpendicular to both 4 Y surfaces and the mid-plane. For most of the structures with 3 parallel surfaces, such as pipes, shells and external nozzles, this X criteria can be easily met. However, in the irregular areas such as in the nozzle to shell juncture, rational planes of bending may be approximated so as to be perpendicular to the mid-plane and have the same angle between the section and the surface on both sides (see Chapter 6). Define an Sm-T curve. Typical values of Sm are given in Tables I-1.1 and I-1.2 of Reference 5.

2.

In de x

COSMOSM Advanced Modules

2-7

Chapter 2 Analysis 3.

If an Sm-T curve is defined, the calculation should proceed by evaluating the equivalent linearized stresses along the defined section (Figure 2-2). The linearized stresses are the sum of the bending stresses and the membrane stresses as outlined in Chapter 1.
Figure 2-2. Equivalent Linearized Stress Along a Sections
S

Actual Stress Bending at X

Linear Stress
(Membrane + Bending)

Membrane

Along Sect ion

4.

Each alternating stress intensity (evaluated according to the Normal Procedure section) is increased by a factor Ke. This factor is determined by considering an equivalent alternating stress intensity based on linearized stresses (see Chapter 6).

In de x

2-8

COSMOSM Advanced Modules

Description of Elements

Introduction
The following table shows the elements that are used in the FSTAR program. For detailed descriptions of each element, you are referred to Chapter 4 of the COSMOSM User Guide manual.
Table 3-1. Elements for FSTAR Element Type 2D Spar/Truss 2D Elastic Beam 3D Elastic Beam 3D Spar/Truss Elastic Straight Pipe Boundary Element General Mass Element Elastic Curved Pipe 2D 4- to 8-Node Plane Stress, Strain, Body of Revolution 3D 3- to 6-Node Plane Stress, Strain, Body of Revolution Triangular Thick Shell Quadrilateral Thick Shell 3D 8- to 20-Node Continuum Brick Element Name TRUSS2D BEAM2D BEAM3D TRUSS3D PIPE BOUND MASS ELBOW PLANE2D TRIANG SHELL3T SHELL4T SOLID

In de x

COSMOSM Advanced Modules

3-1

Part 2 FSTAR / Fatigue Analysis

Table 3-1. Elements for FSTAR (Concluded) Element Type 3D 4-Node Tetrahedron Solid 3D 10-Node Tetrahedron Solid 2-Node Gap/with Friction Triangular Composite Shell Quadrilateral Composite Shell Triangular Thin Shell Quadrilateral Thin Shell Spring Element 3D 4-Node Tetrahedron Solid with Rotation Axisymmetric Shell General Stiffness 8 or 9-Node Isoparametric Shell Element 8 or 9-Node Isoparametric Composite Shell 8-Node Composite Solid 2-Node Rigid Bar 3D 8- to 20-Node Isoparametric Piezoelectric Solid 6-Node Shell Element Element Name TETRA4 TETRA10 GAP SHELL3L SH3LL4L SHELL3 SHELL4 SPRING TETRA4R SHELLAX GENSTIF SHELL9 SHELL9L SOLIDL RBAR SOLIDPZ SHELL6

In de x

COSMOSM Advanced Modules

3-2

Brief Description of Commands

Introduction
This chapter outlines the commands most commonly used.

Commands Likely to be Used for a Given Analysis

The following section gives a brief description of commands that may be necessary to run a given type of analysis once a proper finite element mesh is generated. This is intended as a general guideline only because the problem at hand may not need all the commands that are mentioned below or it may need some other commands which are not mentioned.

In de x

COSMOSM Advanced Modules

4-1

Chapter 4 Brief Description of Commands

Analysis Menu (Analysis > FATIGUE)

Command FT_EVENT ( ...> Event Cycle) FT_LOAD ( ...> Fatigue Load) FT_STREAD ( ...> Apply Stress) FT_CURDEF ( ...> Property Curve) FT_LOC ( ...> Fatigue Location) FT_SEC ( ...> Fatigue Section) A_FATIGUE ( ...> Analysis Options) R_FATIGUE ( ...> Run Fatigue Analysis) Intended Use

Specifies the number of cycles Defines fatigue loading Defines stress conditions Defines fatigue properties Defines a fatigue location Defines a section for elastic-plastic formulation Specifies the face and layer number of multilayered shell or solids Performs the fatigue analysis

Analysis Menu (Analysis > FATIGUE > FATIGUE LIST)

Command FT_EVENTLIS ( ...> Events) FT_STLIST ( ...> Stress Conditions) FT_CURLIST ( ...> Property Curves) FT_LOCLIST ( ...> Locations) FT_SECLIST ( ...> Sections) Intended Use

List fatigue events and their specifications Lists stress conditions Lists all defined fatigue properties Lists specifications for a pattern of fatigue locations Lists specifications for a pattern of fatigue sections

In de x

4-2

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

Analysis Menu (Analysis > FATIGUE > FATIGUE DELETION)

Command FT_EVENTDEL ( ...> Events) FT_LOADDEL ( ...> Loads) FT_STDEL ( ...> Stresses) FT_CURDEL ( ...> Property Curves) FT_LOCDEL ( ...> Locations) FT_SECDEL ( ...> Sections) Intended Use

Deletes a pattern of fatigue events Deletes a pattern of fatigue loadings Deletes stresses associated with a pattern of fatigue locations Deletes fatigue property specifications Deletes a pattern of fatigue locations Deletes a pattern of fatigue sections

Results Menu (Results > PLOT)

Command ACTFTG ( ...> Fatigue) FTGPLOT ( ...> Fatigue) FTGLIST ( ...> LIST > Events) Intended Use

Loads the cumulative fatigue usage factors into the plot buffers Plots the previously loaded fatigue cumulative factor Lists the cumulative fatigue usage factors

In de x

COSMOSM Advanced Modules

4-3

In de x

4-4

COSMOSM Advanced Modules

Detailed Description of Examples

Introduction
These example are typical fatigue problems solved by the FSTAR module. A detailed description of the steps required to set up and solve the problems are given.

How FSTAR Works

Typical input sequence prior to running the FATIGUE module is:
1.

Define the required events with the FT_EVENT (Analysis > FATIGUE > Event
Cycle) command.

2.

Define fatigue loadings using the FT_LOAD (Analysis > FATIGUE > Fatigue Load) command and associate them with the stresses stored by the COSMOSM structural solution. [Stresses are available for fatigue analysis from the nonlinear module only for those time steps which are specified by the NL_PLOT (Analysis > NONLINEAR > Plot Options) command and for Advanced Dynamics, for those specified by the PD_PLOT (Analysis > POST_DYNAMIC > PD_OUTPUT > Set Plot Options) command].

In de x

COSMOSM Advanced Modules

5-1

Chapter 5 Detailed Description of Examples 3.

You may use the FT_STREAD (Analysis > FATIGUE > Apply Stress) command to input stresses directly. (This command may also be used to modify stresses stored as the result of the initial finite element structural solution). Define fatigue locations with the FT_LOC (Analysis > FATIGUE > Fatigue Location) command. (Not required for all-nodes calculation option). Define fatigue design curves (the S-N curves) with the FT_CURDEF (Analysis > FATIGUE > Property Curve) command or use the A_FATIGUE (Analysis > FATIGUE > Analysis Options) command to specify one of the two pre-defined (optional) S-N curves. Modulus of elasticity must be defined in psi (using the MPROP (Propsets > Material Property) command), if an optional design curve is considered. The predefined (optional) curves are defined in psi versus cycle. (If no S-N curve is defined, the fatigue calculation will not produce usage factors). For shell elements specify the top or bottom face and the layer number with the A_FATIGUE (Analysis > FATIGUE > Analysis Options) command. Activate a location for fatigue calculation with the ACTSET, LOC, ... (Control > ACTIVATE > Set Entity, Loc) command (for the all-nodes option activate zero location). Run the FSTAR module by executing the R_FATIGUE (Analysis > FATIGUE > Run Fatigue Analysis) command. Repeat steps (7) and (8) for other locations if the calculations are made on the basis of one location at a time. If you intend to save the results of the previous calculations in the output file, activate the append flag of the PRINT_OPS (Analysis > OUTPUT OPTIONS > Set Print Options) command.

4.

5.

6.

7.

8.

9.

You may review all your inputs at any time during the editing session or afterward by using commands: FT_EVENTLIS (Analysis > FATIGUE > FATIGUE LIST > Events), FT_LOCLIST (Analysis > FATIGUE > FATIGUE LIST > Locations), FT_CURLIST (Analysis > FATIGUE > FATIGUE LIST > Property Curves), FT_STLIST (Analysis > FATIGUE > FATIGUE LIST > Stress Conditions) or review the result of fatigue calculations after each run with the command: FTGLIST (Results > LIST > Fatigue Usage Factor)

In de x

5-2

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

You can also check both the inputs and outputs by reviewing the file with the extension .FTG. You may delete/ modify your inputs at anytime during the editing session by using the commands: FT_EVENTDEL (Analysis > FATIGUE > FATIGUE LIST > Events), FT_LOADDEL (Analysis > FATIGUE > FATIGUE DELETION > Loads), FT_LOCDEL (Analysis > FATIGUE > FATIGUE DELETION > Locations), FT_STDEL (Analysis > FATIGUE > FATIGUE DELETION > Stresses), FT_CURDEL (Analysis > FATIGUE > FATIGUE DELETION > Property Curves). You may have color plots of the results (for all-nodes option) by issuing ACTFTG and FTGPLOT (Results > PLOT > Fatigue) commands. For the simplified elastic-plastic calculation (for axisymmetric models) add the following steps:
10.

Define a section through the wall thickness with the FT_SEC (Analysis > FATIGUE > Fatigue Section) command (first define locations at the two ends of the section by using the FT_LOC (Analysis > FATIGUE > Fatigue Location) command) Define the Sm-T curve and material parameters M and N with the FT_CURDEF (Analysis > FATIGUE > Property Curve) command. Activate one of the two end locations and run fatigue (steps g and h).

11.

12.

You may use the FT_SECLIST (Analysis > FATIGUE > FATIGUE LIST > Sections), FT_CURLIST (Analysis > FATIGUE > FATIGUE LIST > Property Curves), FT_SECDEL (Analysis > FATIGUE > FATIGUE DELETION > Sections), and FT_CURDEL (Analysis > FATIGUE > FATIGUE DELETION > Property Curves), commands for the listing and deleting of the inputs in steps j and k. The following three examples are designed to clarify the concept of cumulative damage theory and to show how it is implemented in the COSMOSM Fatigue module.

In de x

COSMOSM Advanced Modules

5-3

Chapter 5 Detailed Description of Examples

Cylinder Under Axial Cyclic Loading Example

(Without the use of the processing phase modules.) A cylindrical specimen is under axial cyclic loading with three different amplitudes. One type of stress cycle (event 1) produces 800 cycles of a stress difference variation from zero to +50,000 psi and a second type of stress cycle (event 2) produces 2300 cycles of a stress difference variation from zero to -30,000 psi and a third type produces 1200 cycles of a stress difference variation from zero to +20,000 psi (event 3). The cumulative effect shall be evaluated as stipulated in steps 1 to 9 below.

History Loading
The load history is defined according to Figure 5-1. The number of cycles for each event is specified by n1, n2 and n3.
Figure 5-1. Loading History

x (psi) x
50,000 P

20,000

-30,000
Event 1 n1 = 800 Event 2 Event 3 n2 = 2300 n3 = 1200

Starting The Problem

Move to the working directory and launch GEOSTAR. If you wish, you may use a title for your problem using the command TITLE (Control > MISCELLANEOUS > Write Title).

In de x

5-4

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

Specifying the Fatigue Events

Geo Panel: Analysis > FATIGUE > Event Cycle (FT_EVENT) Reference number for the event > 1 Number of required cycles > 800 Geo Panel: Analysis > FATIGUE > Event Cycle (FT_EVENT) Reference number for the event > 2 Number of required cycles > 2300 Geo Panel: Analysis > FATIGUE > Event Cycle (FT_EVENT) Reference number for the event > 3 Number of required cycles > 1200

You may modify/correct any event specification by repeating command FT_EVENT (Analysis > FATIGUE > Event Cycle) for that event. To delete an event use command FT_EVENTDEL (AnalysIs > FATIGUE > FATIGUE DELETION > Events).

Defining the Loading

Define loadings which correspond to the extremes of excursion within each event. Considering the loading set in Figure 5-2 we shall define the following loadings:
Geo Panel: Analysis > FATIGUE > Fatigue
Load (FT_LOAD) Figure 5-2. Loading History

x (psi)
2 Loading

6 1 3

Reference number> 1 Associated event > 1 Associated load case > 0

No stresses for this loading

In de x

Geo Panel: Analysis > FATIGUE > Fatigue Load (FT_LOAD) Reference number> 2 Associated event > 1 Associated load case > -1

COSMOSM Advanced Modules

5-5

Chapter 5 Detailed Description of Examples

Geo Panel: Analysis > FATIGUE > Fatigue Load (FT_LOAD) Reference number> 3 Associated event > 2 Associated load case > 0 Geo Panel: Analysis > FATIGUE > Fatigue Load (FT_LOAD) Reference number > 4 Associated event > 2 Associated load case > -1 Geo Panel: Analysis > FATIGUE > Fatigue Load (FT_LOAD) Reference number > 5 Associated event > 3 Associated load case > 0 Geo Panel: Analysis > FATIGUE > Fatigue Load (FT_LOAD) Reference number > 6 Associated event > 3 Associated load case > -1

You may review all your input so far by using list command FT_EVENTLIS (Analysis > FATIGUE > FATIGUE LIST > Events). You may modify/correct any loading specification by repeating command FT_LOAD (Analysis > FATIGUE > Fatigue Load), or may delete a loading by using command FT_LOADDEL (Analysis > FATIGUE > FATIGUE DELETION > Loads).

Caution: Deleting an event erases all loadings which were associated to that
event, i.e., all parameters which are otherwise listed for that event [using command FT_EVENTLIS (AnalysIs > FATIGUE > FATIGUE LIST > Events)] will be deleted.

Defining a Location
Define a location for fatigue calculation.
Geo Panel: Analysis > FATIGUE > Fatigue Location (FT_LOC) Reference number for fatigue location > 1 Associated node label > 1

For this example Node label is irrelevant. It is useful for problems for which the stress conditions are available in the database from initial COSMOSM processing phase calculations.
In de x

Stress concentration in X dir > 1.0 Stress concentration in Y dir > 1.0

5-6

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

Stress concentration in Z dir > 1.0

Stress concentration factors are considered to be unity in all directions. You may review your inputs by using list command FT_LOCLIST (Analysis > FATIGUE > FATIGUE LIST > Locations) (use default for all prompts). Dashed lines under headings X, Y, Z, and CS are due to the irrelevance of nodal coordinates in this example.

Specifying the Stress

Specify the stress conditions for the defined loadings (as are specified in Figure 5-2) and location.
Geo Panel: Analysis > FATIGUE > Apply Stress (FT_STREAD) Location label > 1 Fatigue loading label > 2 Item number > Actual stresses Normal stress in X direction > 50000 Normal stress in Y direction > 0.0 Normal stress in Z direction > 0.0 Shear stress TAU_XY > 0.0 Shear stress TAU_XZ > 0.0 Shear stress TAU_YZ > 0.0

(For location 1, loading 2, define SX = 50,000. All other stress components are zero).
Geo Panel: Analysis > FATIGUE > Apply Stress (FT_STREAD) Location label > 1 Fatigue loading label > 4 Item number > Actual stresses Normal stress in X direction > -30000 Normal stress in Y direction > 0.0 Normal stress in Z direction > 0.0 Shear stress TAU_XY > 0.0 Shear stress TAU_XZ > 0.0 Shear stress TAU_YZ > 0.0 Geo Panel: Analysis > FATIGUE > Apply Stress (FT_STREAD) Location label > 1 Fatigue loading label > 6
In de x

COSMOSM Advanced Modules

5-7

Chapter 5 Detailed Description of Examples

Item number > Actual stresses Normal stress in X direction > -20000 Normal stress in Y direction > 0.0 Normal stress in Z direction > 0.0 Shear stress TAU_XY > 0.0 Shear stress TAU_XZ > 0.0 Shear stress TAU_YZ > 0.0

To review the stress conditions specified by command FT_STREAD (Analysis > FATIGUE > Apply Stress) use list command FT_STLIST (Analysis > FATIGUE > FATIGUE LIST > Stress Conditions).
Geo Panel: Analysis > FATIGUE > FATIGUE LIST > Stress Conditions
(FT_STLIST)

First location > 1 Last location > 1 Increment > 1 Loading label > All loadings Item number > Actual stresses

You may use command FT_STREAD (Analysis > FATIGUE > Apply Stress) to modify any stored stress condition (stress may have been stored by using command FT_STREAD (Analysis > FATIGUE > Apply Stress) or pre-stored in the data base in the processing phase) for any combination of location and loading. Command FT_STDEL (Analysis > FATIGUE > FATIGUE DELETION > Stresses) may be used to delete stress conditions stored using command FT_STREAD (Analysis > FATIGUE > Apply Stress).

Specifying the Fatigue Curve

Specify the fatigue design curve (S-N curve) using command FT_CURDEF (Analysis > FATIGUE > Property Curve).
Geo Panel: Analysis > FATIGUE > Property Curve (FT_CURDEF) Curve/prop item number > 1

Default implies that the user is going to specify points on the S-N curve
Stress ratio R > -1

Min. over Max. Stress. Default -1 implies a fully reversible stress cycling

In de x

5-8

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

Cycles at point 1 > 2000 Stress at point 1 > 80E3 Cycles at point 2 > 5000 Stress at point 2 > 50E3 Cycles at point 3 > 40000 Stress at point 3 > 30E3 Cycles at point 4 > 500000 Stress at point 4 > 20E3

To input the fifth point, the command must be re-issued.

Geo Panel: Analysis > FATIGUE > Property Curve (FT_CURDEF) Curve/prop item number > 1 Stress ratio R > -1 Cycles at point 5 > 100000000 Stress at point 5 > 19E3 Figure 5-3. Cycles at point 6 >
80

Defined Fatigue Design Curve (S-N Curve)

To review your inputs for the fatigue design curve you may use the commands ACTXYPRE (Display > XY PLOTS > Activate Pre-Proc) and XYPLOT (Display > XY PLOTS > Plot Curves). The above five points define a fatigue design curve according to Figure 5-3.

60

a lt

x x
20

(ksi) 40

x
4 5 6 7

x
10

0 3 10

10

10

10

10 8

Cycle

Geo Panel: Display > XY PLOTS > Activate Pre-Proc (ACTXYPRE) Graph number > 1 Curve type > Fatigue Curve type > SN Curve number > 1 Graph color > 12 Graph line style > Solid Graph symbol style > Circle Geo Panel: Display > XY PLOTS > Plot Curves (XYPLOT)

In de x

COSMOSM Advanced Modules

5-9

Chapter 5 Detailed Description of Examples

Running the Fatigue Analysis

Through steps 1 to 7, all necessary data are stored in the database. In order to make a fatigue calculation at a location, first we have to activate that location.

In de x

5-10

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

Geo Panel: Control > ACTIVATE > Set Entity (ACTSET) Set label > Loc Location for fatigue calculation > 1

(This is necessary because the program is designed in such a way that the user may define more than one location). To run the fatigue problem, use command R_FATIGUE (Analysis > FATIGUE > Run Fatigue Analysis). When the analysis is complete, the program will return to the GEOSTAR menu. The resulting outputs are stored in the output file with extension .FTG. The results may be reviewed either with the editor, using the command EDIT (File > Edit...), or using the list command FTGLIST (Results > LIST > Fatigue Usage Factor).
Geo Panel: Results > LIST > Fatigue Usage Factor (FTGLIST) Location label > 1

Lists the latest results for location 1 (see Figure 5-4.):

Table Table 5-1. List of Results Loading (EVN) 2 4 3 1 2 2 Loading (EVN) 4 6 4 2 3 2 Cycles Used 800 1200 300 Allowed 0.1240E+05 0.1245E+06 0.1000E+09 Alternate Stress 4000 25000 15000 Partial Factor 0.64510E-01 0.96357E-02 0.30000E-05

Cumulative Fatigue Usage Factor = 0.741483E-01

Total Solution Time = 3 seconds

Interpretation of the Results

A cumulative fatigue usage factor of 0.074 means that 7.4% of the life of the component (structure) is used up by this combination of events. It is interesting to note that even though the number of the loading combinations is 9 for this example, there are only three sets which produce partial factors. There are basically two reasons for this. First, loadings with identical stress conditions produce zero alternating stress intensities. Secondly, updating the alternating stress intensity list every time one of the partial factors is evaluated (Analysis Procedure For Cyclic Loading section), results in the elimination of some of the remaining sets in the list (e.g., the combination of loadings 2 and 6 makes no contribution).

In de x

COSMOSM Advanced Modules

5-11

Chapter 5 Detailed Description of Examples Table 5-2. Results [Reference 1] Theoretical Fatigue usage factor at location 1 7.4% COSMOSM 7.4%

For more complicated problems, often an initial finite element structural analysis is necessary in order to find the stress conditions. The following example illustrates the use of COSMOSM. Modules such as STAR, NSTAR, or HSTAR, to evaluate the stress conditions needed for fatigue analysis.

Fatigue Caused by Pressure Loading Example

(This example is based on using the processing phase module, STAR, in the Basic System.) A circular nozzle is under a varying internal pressure. Figure 5-4 shows the model and the internal pressure cycle. In addition to a normal pressure build up which is expected to occur 10,000 times during the service life, the component is expected to experience an abnormal condition which occurs only 2000 times with the characteristics illustrated in Figure 5-4.
Figure 5-4. Geometry and Load Cycle

1" C L 2" 2"

P (psi) 3
20,000
x

P
2"
x

2
10,000
x

x Loading

1"

4"
x

1
0.02 Event 1 0.1 0.12

4 t

3" 5"

2"

0.2 0.22

Event 2 (2000 cyc)

(10,000 cyc)

In de x

5-12

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

To evaluate the usage factor (percentage of life used up) at different locations, first the stress conditions at extreme points within a cycle will be evaluated. Therefore, we need only to evaluate the stress field for the two stress levels 10,000 and 20,000 psi.

Given
E = 30 x 106 psi = 0.3

The processing phase consists of the following three steps.

Structural Modeling and Stress Analysis

Type the following cryptic input in the command window.
GEO> VIEW,0,0,1,0, GEO> PLANE,Z,0,1, GEO> GRIDON,,,1,1,10,10,, GEO> SCALE,0, GEO> PT,1,8,0,0, GEO> PT,2,6,0,0, GEO> PT,3,3,0,0, GEO> PT,4,3,3,0, GEO> PT,5,3,6,0, GEO> PT,6,3,8,0, GEO> PT,7,3,10,0, GEO> PT,8,4,10,0, GEO> PT,9,4,8,0, GEO> PT,10,5,6,0, GEO> PT,11,5,3,0, GEO> PT,12,6,2,0, GEO> PT,13,8,2,0, GEO> PT,14,6,3,0, GEO> CRLINE,1,1,2, GEO> CRLINE,2,2,3, GEO> CRLINE,3,3,4, GEO> CRLINE,4,4,5, GEO> CRLINE,5,5,6, GEO> CRLINE,6,6,7, GEO> CRLINE,7,7,8, GEO> CRLINE,8,8,9, GEO> CRLINE,9,9,10, GEO> CRLINE,10,10,11, GEO> CRPCIRCLE,11,14,12,1,-90,1, GEO> CRLINE,12,12,13, GEO > CRLINE,13,13,1 GEO> CRBRK,11,11,1,2,0, GEO> SF2CR,1,1,12,0, GEO> ACTMARK,SF, GEO> SF2CR,2,2,11,0, GEO> SF2CR,3,3,14,0, GEO> SF2CR,4,4,10,0, GEO> CRLINE,13,13,1, GEO> SF2CR,5,5,9,0, GEO> SF2CR,6,6,8,0, GEO> EGROUP,1,PLANE2D,0,1,1,0,0,0,0,0, GEO> MPROP,1,EX,3.D7, GEO> MPROP,1,NUXY,.3, GEO> MPROP,1,DENS,.0003, GEO> M_SF,1,3,1,4,4,4,1,1, GEO> M_SF,5,6,1,4,4,4,1,1, GEO> M_SF,4,4,1,4,6,4,1,1, GEO> NMERGE,1,160,1,0.0001,0,1,0, GEO> DCR,1,UY,0,2,1,, GEO> ACTSET,LC,1 GEO> PEL,33,10000.0,1,36,1, GEO> PEL,81,10000.0,1,86,1, GEO> PEL,49,10000.0,1,52,1, GEO> PEL,65,10000.0,1,68,1, GEO> ACTSET,LC,2 GEO> PEL,33,20000.0,1,36,1, GEO> PEL,81,20000.0,1,86,1, GEO> PEL,49,20000.0,1,52,1, GEO> PEL,65,20000.0,1,68,1, GEO> A_STATIC,N,0,0,1e-06,1e+10,0,0,0, GEO> R_STATIC

In de x

COSMOSM Advanced Modules

5-13

Chapter 5 Detailed Description of Examples

At this stage you have the option of analyzing the fatigue problem at one location (node) at a time or at all nodes at once. The first option provides you with more details of the calculation. However, the all nodes option relieves you from the painstaking task of studying each location one by one and provides you with a graphical display of the fatigue life. These options are outlined in the following:

Fatigue Analysis (Normal Procedure, i.e., One Location at a Time)

1.

It is recommended to first identify the areas of stress concentration. This may be done, quantitatively, by studying the stress distribution inside the structure using commands in the Results menu. From the displayed contours it is apparent that the tip of the nozzle, at node 105, experiences the highest level of stress.
Geo Panel: Analysis > FATIGUE > Event Cycle (FT_EVENT) Reference number for the event > 1 Number of required cycles > 10000 Geo Panel: Analysis > FATIGUE > Event Cycle (FT_EVENT) Reference number for the event > 2 Number of required cycles > 2000 Geo Panel: Analysis > FATIGUE > Fatigue Load (FT_LOAD) Reference number > 1 Associated event > 1 Associated load case > 0

Zero stresses at all locations

Geo Panel: Analysis > FATIGUE > Fatigue Load (FT_LOAD) Reference number > 2 Associated event > 1 Associated load case > 1 Scale factor > 1 Geo Panel: Analysis > FATIGUE > Fatigue Load (FT_LOAD) Reference number > 3 Associated event > 2 Associated load case > 2
In de x

Scale factor > 1

5-14

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

Geo Panel: Analysis > FATIGUE > Fatigue Load (FT_LOAD) Reference number > 4 Associated event > 2 Associated load case > 0 Geo Panel: Analysis > FATIGUE > Fatigue Location (FT_LOC) Reference number for fatigue location > 1 Associated node label > 105 Stress concentration in X dir > 1.0 Stress concentration in Y dir > 1.0 Stress concentration in Z dir > 1.0 Geo Panel: Analysis > FATIGUE > Property Curve (FT_CURDEF) Curve/prop item number > 1 Stress ratio R > -1 Cycles at point 1 > 2000 Stress at point 1 > 80E3 Cycles at point 2 > 4000 Stress at point 2 > 60E3 Cycles at point 3 > 10000 Stress at point 3 > 30E3 Cycles at point 4 > 100000 Stress at point 4 > 5E3 Geo Panel: Analysis > FATIGUE > Property Curve (FT_CURDEF) Curve/prop item number > 1 Stress ratio R > -1 Cycles at point 5 > 10000000 Stress at point 5 > 1E3 Geo Panel: Analysis > OUTPUT OPTIONS > Set Print Options (PRINT_OPS) Displacement print flag > Yes ... Output flag > Append Geo Panel: Control > ACTIVATE > Set Entity (ACTSET) Set label > Loc Location for fatigue calculation > 1
In de x

COSMOSM Advanced Modules

5-15

Chapter 5 Detailed Description of Examples

Geo Panel: Analysis > FATIGUE > Run Fatigue Analysis (R_FATIGUE)

Perform fatigue calculations

Geo Panel: Results > LIST > Fatigue Usage Factor (FTGLIST)

List fatigue results for location 1

2.

You may review the output file by using the EDIT (File > Edit...) command.
Geo Panel: File > Edit a File (EDIT)

Review all results

3.

You may continue by defining new locations.

There are other alternative ways of solving a linear static problem such as the

one considered above which may significantly reduce the computational time. One alternative to the above is running the static problem for only one load case (e.g., load case 1) and then associating fatigue loadings 2 and 3 with that load case with a scale factor of 1 and 2.0, respectively.

4.

This results in the modification of structural modeling part of the problem as follows (type the cryptic input in the command window):
GEO> ACTSET,LC,1 GEO> PEL,33,10000.0,1,36,1, GEO> PEL,81,10000.0,1,86,1, GEO> PEL,49,10000.0,1,52,1, GEO> PEL,65,10000.0,1,68,1, GEO> A_STATIC,N,0,0,1e-06,1e+10,0,0,0, GEO> R_STATIC

and of Fatigue Analysis part of the problem:

. . .

GEO> FT_LOAD,2,1,1,1 GEO> FT_LOAD,3,2,1,2

. . . 5.

In de x

The above modification is applicable only to the linearly elastic materials for which the stress (response) is linearly proportional to the applied load.

5-16

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

Fatigue Analysis (All-Nodes Option)

Type the following cryptic input in the command window.
GEO> FT_EVENT,1,10000 GEO> FT_EVENT,2,2000 GEO> FT_LOAD,1,1,0 GEO> FT_LOAD,2,1,1,1 GEO> FT_LOAD,3,2,2,1 GEO> FT_LOAD,4,2,0 GEO> FT_CURDEF,1,,2000,80E3,4000,60E3,10000,30E3,100000,5E3 GEO> FT_CURDEF,1,1000000,1E3 GEO> ACTSET,LOC,0

Activate all-nodes option

GEO> R_FATIGUE

Perform fatigue calculations

GEO> FTGLIST,0

List the fatigue results at all nodes

1.

You may review the output file by using the EDIT (File > Edit...) command, or issuing the SYSTEM command and using your favorite editor.
Geo Panel: File > Edit... (EDIT)

Review results
2.

At this step, you may utilize the graphic capability of GEOSTAR to display color plots of the fatigue life and identify fatigue critical regions. Fatigue curves can be plotted using the XYPLOT (Display > XY PLOTS > Plot Curves) command.
Geo Panel: Results > PLOT > Fatigue (ACTFTG)

Fatigue Caused by Thermal Loading Example

(Using the processing phase modules: HSTAR and NSTAR.)
In de x

COSMOSM Advanced Modules

5-17

Chapter 5 Detailed Description of Examples

Assume that the nozzle of example 2 is exposed to a fluid heat up condition which is expected to occur 5000 times during its service life. One complete cycle of this heat up condition is shown in Figure 5-6.

Figure 5-5.

Nozzle Geometry and a Section

1" C L 2" 2"

Given
E Kx h h Tref = 30*10 psi = 0.3 = 8.0E-6 in/in/F = 0.1 BTU/in hr F = 1.0 BTU/in2 hr F (outside surface) = 5.0 BTU/in hr F (inside surface)
2
3"

2"

3 x 1"

4"

2" 5"

Figure 5-6. Temperature Variation Cycle

= 60 F

Tmax = 300 F

Creating the Model Geometry

Structural modeling (similar to the thermal loading example); type the following cryptic input in the command window.
TEMP.

T e m p e r a t u r e

300

150

60 0 0.02 0.1 0.12 Time (HR) 0.2

GEO> TITLE, FT3A: FATIGUE OF A NOZZEL WITH CYCLIC INTERNAL FLUID GEO> PLANE,Z,0,1, GEO> VIEW,0,0,1,0, GEO> CRSPOLY,1,8,0,0, L,8,2,0, L,6,2,0, A,5,3,0,

In de x

5-18

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

L,5,6,0, L,4,8,0, L,4,10,0, L,3,10,0 L,3,8,0, L,3,6,0, L,3,3,0, L,3,0,0, L,6,0,0, L,8,0,0, GEO> SCALE,0, GEO> CRBRK,3,3,1,2,0, GEO> SF2CR,1,13,2,0, GEO> SF2CR,2,12,3,0, GEO> SF2CR,3,11,14,0, GEO> SF2CR,4,10,4,0, GEO> SF2CR,5,9,5,0, GEO> SF2CR,6,8,6,0, GEO> EGROUP,1,PLANE2D,0,1,1,0,0,0,0, GEO> M_SF,1,3,1,4,4,4,1,1, GEO> M_SF,5,6,1,4,4,4,1,1, GEO> M_SF,4,4,1,4,6,4,1,1, GEO> DCR,12,UY,0,13,1,,

Specifying and Running the Thermal Analysis

Thermal analysis. Using the HSTAR Module, the nodal temperatures of the structure will be evaluated at time intervals of 0.01 hours. Type the following cryptic input in the command window.
GEO> CURDEF,TIME,1,1,0.000000E+00,60.0000,0.200000E-01,300.000, GEO> CURDEF,TIME,1,3,0.100000,300.000,0.120000,60.0000, GEO> CURDEF,TIME,1,5,0.200000,60.0000, GEO> MPROP,1,ALPX,0.800000E-05, GEO> MPROP,1,DENS,0.300000E-03, GEO> MPROP,1,C,40.0000, GEO> MPROP,1,KX,0.100000, GEO> ACTSET,TC,0, GEO> ACTSET,TP,0,

In de x

COSMOSM Advanced Modules

5-19

Chapter 5 Detailed Description of Examples

GEO> CEL,4,1.,60.,2,16,4,0, GEO> CEL,13,1.,60.,3,16,1,0, GEO> CEL,29,1.,60.,3,32,1,0, GEO> CEL,45,1.,60.,3,48,1,0, GEO> CEL,99,1.,60.,3,104,1,0, GEO> CEL,61,1.,60.,3,64,1,0, GEO> CEL,77,1.,60.,3,80,1,0, GEO> CEL,65,5.,1.,1,68,1,1, GEO> CEL,49,5.,1.,1,52,1,1, GEO> CEL,81,5.,1.,1,86,1,1, GEO> CEL,33,5.,1.,1,36,1,1, GEO> NMERGE,1,160,1,0.0001,0,1,0, GEO> CRMERGE,1,20,1,0.0001,1,1,0, GEO> TIMES,0.000000E+00,0.200000,0.100000E-01, GEO> TUNIF,60.0000, GEO> TOFFSET,273.000, GEO> INITIAL,TEMP,1,159,1,60., GEO> A_THERMAL,T,0.100000E-02,5,1,20,0, GEO> R_THERMAL

Specifying and Running the Stress Analysis

Stress analysis. Type the following cryptic input in the command window.
GEO> MPROP,1,EX,30E6,NUXY,.3, GEO> TREF,60, GEO> A_NONLIN,S,1,1,20,0.001,0,T,0,0, GEO> PRINT_OPT,1,0,0,1,0,1,0,0,0,1, GEO> NL_PLOT,2,20,2,0, GEO> R_NONLINEAR

Stresses are available for postprocessing (fatigue analysis or stress plot) from
the nonlinear module only for those time steps which are specified by command NL_PLOT (Analysis > NONLINEAR > Plot Options).

Specifying and Running the Fatigue Analysis

In de x

Fatigue analysis. Type the following cryptic input in the command window.

5-20

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

GEO> FT_EVENT,1,5000, GEO> FT_LOAD,1,1,2,1, GEO> FT_LOAD,2,1,4,1, GEO> FT_LOAD,3,1,6,1, GEO> FT_LOAD,4,1,8,1, GEO> FT_LOAD,5,1,10,1, GEO> FT_LOAD,6,1,12,1, GEO> FT_LOAD,7,1,14,1, GEO> FT_LOAD,8,1,16,1, GEO> FT_LOAD,9,1,18,1, GEO> FT_LOAD,10,1,20,1, GEO> FT_LOC,1,130,1,1,1, GEO> FT_CURDEF,1,-1,2000,80E3,4000,40E3,10000,10E3,100000,3.E3, GEO> ACTSET,LOC,1, GEO> R_FATIGUE

If you wish to perform fatigue analysis based on a simplified elastic-plastic formulation then continue with:

Running the Analysis Based on the Elastic-Plastic Formulation

Analysis based on elastic-plastic formulation. Type the following cryptic input in the command window.
GEO> FT_LOC,2,51,1,1,1, GEO> FT_LOC,3,71,1,1,1, GEO> FT_SEC,1,2,3,25,-1,1, GEO> ACTSET,LOC,2, GEO> FT_CURDEF,30,2.,.8, GEO> FT_CURDEF,20,60,.5E5,200,.15E5,400,.8E4, GEO> R_FATIGUE

You may review all the results by using either EDIT (File > Edit...) or FTGLIST (Results > LIST > Fatigue Usage Factor) commands.

In de x

COSMOSM Advanced Modules

5-21

In de x

5-22

COSMOSM Advanced Modules

A Brief Theoretical Background for Simplified Elastic-Plastic Formulation

Introduction
This chapter contains additional details on subjects mentioned in earlier chapters.

Section Orientation in Junctions

For sections in the nozzle to shell junctions, rational planes of bending should be approximated such that they are perpendicular to the mid-plane and have the same angle between the section and the surface on both sides. This is done by forming an isosceles triangle which has the section as its base and the mid-plane as its altitude as shown in Figure 6-1. One side of the triangle is tangent to the fillet at the point of interest.
Figure 6-1. Defining a Section in an Irregular Area

C L

In de x

COSMOSM Advanced Modules

6-1

Chapter 6 A Brief Theoretical Background for Simplified Elastic-Plastic Formulation

Stress Linearization
For plane strain, plane stress and axisymmetric structures, stress linearization is performed along a section path. A section is defined by nodes N1 and Nn according to Figure 6-2. The program interpolates n-2 equally spaced (integration) points along the path between nodes N1 and Nn. For each point, structural elements are searched to identify an element which contains that point. Once the element is identified, the stresses at that point are interpolated linearly from the element corner nodes. These stresses are denoted as actual stresses.
Figure 6-2. A Section with n Equally Spaced Integration Points Along its Path

C L

Nn N1 N4 N2 N3 N n-1

The equivalent linearized stresses are found along a section by evaluating the membrane and bending stresses according to one of the following two methods.

Cartesian Formulation (Approximation)

This formulation is applicable to plane stress or plane strain problems or to the axisymmetric structures where the radial dependency could be ignored. For axisymmetric structures, radial dependency is due to the fact that for axisymmetric structures, there is more material at a greater radius than at a smaller one. This option is implemented into the calculation if the input quantity curvature_radius in command FT_SEC (Analysis > FATIGUE > Fatigue Section) is set to zero (see the Axisymmetric Formulation section for the definition of curvature_radius). The membrane components of the stresses are evaluated by integrating along the section path according to:

In de x

6-2

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

(6-1)

where, superscripts m and a correspond to membrane and actual stresses, respectively, l is the length of the section, x and y are the local coordinates along and perpendicular to the section path (Figure 6-3) with an origin at the mid-wall, and X, Y and Z are the global Cartesian coordinates. Membrane stresses are considered to be constant along the section. The bending component of stresses at position x along the section path (Figure 6-3) is calculated according to:

Figure 6-3. Definition of the Section Local Coordinates

C L

y x,

Nn /2

N1 /2 X

(6-2)

where superscript b corresponds to the bending stress. The linearized stress at any point along the section is the sum of membrane and bending stresses.
In de x

COSMOSM Advanced Modules

6-3

Chapter 6 A Brief Theoretical Background for Simplified Elastic-Plastic Formulation

Axisymmetric Formulation
In this case the axisymmetric features of the model is more properly implemented in the formulation, for axisymmetric structures, than the Cartesian case. This option is considered in fatigue calculation if a non-zero value is assigned to the input quantity curvature_radius in command FT_SEC (Analysis > FATIGUE > Fatigue Section). Curvature_radius corresponds to the radius of curvature of the average mid-wall centerline in the xy plane as represented by in Figure 6-4. A large value (or -1) for curvature_radius corresponds to straight walls (e.g., cylinder or cone). In order to find the linearized stresses, it is desired to obtain applied forces and moments along the section. Figure 6-5 represents a freebody diagram of the section. A righthanded local coordinate system, x, y, and z is established on the section with the origin at the mid-wall (same as in Figures 6-3 or 6-4). FN and FT correspond to the inplane normal and shear forces on the section in y and x directions and MZ is the bending moment. The three inplane forces and moment on the section over a small sector in the hoop direction are defined as:
Figure 6-4. Curvature-Radius of the Mid-Wall

C L

x Nm
x

Y N1 X

Figure 6-5. Applied Forces and Moments Along the Section

C L

FT MZ Y

FN

MZ FT
x,

In de x

6-4

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

(6-3)

where, ya and xya are the actual stresses along the section in local coordinates, X is the global coordinate (or equivalently the radius) of point being integrated along the section and xf in local coordinates is the offset of the sector neutral axis from the center line. From FN in the above equation, the average normal membrane stress in the y direction is computed once it is divided by the sector area (Xc is the global coordinate of the mid-section).

(6-4)

The MZ contribution to the normal bending stress in the y direction is computed by applying the familiar relationship s = Mz (x-xf)/I with I as moment of inertia of the sector.

(6-5)

An average membrane shear stress (xy component) is computed by dividing FT [in Equation (6-3)] by the sector area, assuming that xy bending shear stress has insignificant contribution (since the shear stress distribution is assumed to be parabolic and equal to zero at the two free surface ends).

In de x

COSMOSM Advanced Modules

6-5

Chapter 6 A Brief Theoretical Background for Simplified Elastic-Plastic Formulation

(6-6) Average membrane stress in the x direction is computed by averaging the actual stresses along the section according to:

(6-7) The bending stress in the x direction (thickness direction) is ignored if in command FT_SEC (Analysis > FATIGUE > Fatigue Section) the corresponding flag is set to one, otherwise it is approximated at the two ends as the difference of the actual and membrane stresses. The hoop membrane and bending stresses are calculated by considering a small sector () in the XY plane. By integrating the total normal force on the sector and averaging it over the corresponding area, the average membrane stress (in hoop direction) is computed according to:

(6-8)

For straight walls where , Equation (6-8) reduces to the familiar form. The hoop bending stress is calculated by evaluating the applied bending moment on the sector. Once the bending moment is evaluated, the hoop bending stress is found analogous to that of the y direction bending stress.

(6-9)

In de x

6-6

COSMOSM Advanced Modules

Part 2 FSTAR / Fatigue Analysis

As mentioned before, the linearized stress at any point along the section is the sum of membrane and bending stresses.

Simplified Elastic-Plastic Option

For a desired location (e.g., at one end of a section), each alternating stress intensity (evaluated according to Chapter 2) is increased by a factor Ke (Reference 1). This factor is a function of the equivalent linearized alternating stress intensity L as well as the design stress m interpolated from the Sm-T curve. The equivalent linearized alternating stress intensity is evaluated analogously to the alternating stress intensity, based on the linear stresses, not actual stresses. Factor Ke is defined for different ranges of L as follows: (6-10)

(6-11)

(6-12) where, M and N are the elastic-plastic material parameters (input quantities on FT_CURDEF (Analysis > FATIGUE > Property Curve) command). References
1.

ASME Boiler and Pressure Vessel Code, Edition 1983, Section III, Division 1, Subsection NB. Kroenke, W. C., Addicott, G. W. and Hinton, B. M., Interpretation of Finite Element Stresses According to ASME Section III, Paper 75-PVP-63, ASME Second National Congress on Pressure Vessels and Piping, June 1975. Kroenke, W. C., Classification of Finite Element Stresses According to ASME Section III Stress Categories, Pressure Vessels and Piping, Analysis and Computer, ASME, June 1974.

2.

3.

In de x

COSMOSM Advanced Modules

6-7

Chapter 6 A Brief Theoretical Background for Simplified Elastic-Plastic Formulation 4.

Gordon, J. L., Outcur: An Automated Evaluation of Two-Dimensional Finite Element Stresses According to ASME Section III Stress Requirements, Paper 76-WA/PVP-16, December 1976. ASME Boiler and Pressure Vessel Code, Edition 1989, Section III, Division 1, Appendices.

5.

In de x

6-8

COSMOSM Advanced Modules

Index

A Analysis Options 4-2, 5-2 Apply Stress 4-2, 5-2, 5-7, 5-8 ASME Boiler and Pressure Vessel Code 1-2, 6-7, 6-8 B Bending Stress 6-3, 6-5, 6-6 D Design Stress 6-7 E elastic-plastic formulation 1-2,
4-2, 5-21, 6-1 Event Cycle 4-2, 5-1, 5-5, 5-14 Events 1-1, 4-2, 4-3, 5-1, 5-2, 5-3, 5-5, 5-6, 5-11

fatigue design curve 5-8, 5-9 fatigue life 1-2, 5-14, 5-17 fatigue loading 4-2, 5-7 Fatigue Location 4-2, 5-2, 5-3, 5fatigue properties 4-2 Fatigue Section 4-2, 5-3, 6-2, 6-4, fatigue usage factor 1-1, 1-2, 5-2,
5-11, 5-12, 5-16, 5-21 6-6 6, 5-15

S Sections 4-2, 4-3, 5-3, 6-1 Set Entity 5-2, 5-11, 5-15 Sm-T Curve 5-3, 6-7 S-N curve 5-2, 5-8, 5-9 Stress Conditions 1-1, 4-2, 5-2, 5Stresses 1-1, 4-3, 5-1, 5-2, 5-3, 55, 5-7, 5-8, 5-14, 5-20, 6-2, 6-3, 64, 6-5, 6-6, 6-7, 6-8 6, 5-7, 5-8, 5-11, 5-12, 5-13

L Linearized Stress 6-3, 6-7 load history 5-4 Loads 1-1, 4-3, 5-3, 5-6 Locations 4-2, 4-3, 5-2, 5-3, 5-7,
5-13, 5-14, 5-16

U usage factor 1-1, 1-2, 5-2, 5-11, 512, 5-13, 5-16, 5-21

F Fatigue 1-1, 1-2, 4-2, 4-3, 5-1, 5-2,

5-3, 5-5, 5-6, 5-7, 5-8, 5-9, 5-10, 511, 5-12, 5-14, 5-15, 5-16, 5-17, 518, 5-20, 5-21, 6-2, 6-4, 6-6, 6-7 Fatigue Analysis 1-1, 4-2, 5-1, 52, 5-10, 5-11, 5-12, 5-14, 5-16, 517, 5-20, 5-21 fatigue curve 5-8

M Material Property 5-2 Membrane Stress 6-5, 6-6 P Plot Curves 5-9, 5-17 Plot Options 5-1, 5-20 Print Options 5-2, 5-15 Property Curves 4-2, 4-3, 5-2, 5-3

In de x

COSMOSM Advanced Modules

I-1