Fatigue Analysis

It is observed that repeated loading and unloading weakens objects over time even when the induced stresses are
considerably less than the allowable stress limits. This phenomenon is known as fatigue. Each cycle of stress fluctuation
weakens the object to some extent. After a number of cycles, the object becomes so weak that it fails. Fatigue is the prime
cause of the failure of many objects, especially those made of metals. Examples of failure due to fatigue include, rotating
machinery, bolts, airplane wings, consumer products, offshore platforms, ships, vehicle axles, bridges, and bones.

Linear and nonlinear structural studies do not predict failure due to fatigue. They calculate the response of a design subjected
to a specified environment of restraints and loads. If the analysis assumptions are observed and the calculated stresses are
within the allowable limits, they conclude that the design is safe in this environment regardless of how many times the load is
applied.

Results of static, nonlinear, or time history linear dynamic studies can be used as the basis for defining a fatigue study. The
number of cycles required for fatigue failure to occur at a location depends on the material and the stress fluctuations. This
information, for a certain material, is provided by a curve called the SN curve.

Stages of Failure Due to Fatigue

Failure due to fatigue occurs in three stages:

Stage One or more cracks develop in the material. Cracks can develop anywhere in the material but
1 usually occur on the boundary faces due to higher stress fluctuations. Cracks can occur due to many
reasons. Imperfections in the microscopic structure of the materials and surface scratches caused by
tooling or handling are some of them.

Stage Some or all the cracks grow as a result of continued loading.

2

Stage The ability of the design to withstand the applied loads continue to deteriorate until failure occurs.
3

Fatigue cracks start on the surface of a material. Strengthening the surfaces of the model increases the life of the model under
fatigue events.

Definitions for Fatigue

Endurance Limit As the alternating stress gets smaller, the material can take more
stress cycles before it fails due to fatigue. The endurance limit is the
highest alternating stress that does not result in fatigue failure. In
other words, if the alternating stress is equal to or lower than the
endurance limit, the number of stress cycles to cause failure
becomes very large (practically infinite). The endurance limit is
usually defined for zero-mean alternating stresses. The endurance
limit is also called the fatigue limit. Some metals do not have a
measurable endurance limit.

Alternating Stress The alternating stress is defined as |(σmax - σmin)| / 2 where σmax and In Simulation, you can set the stress
σmin are the maximum and minimum stresses respectively. component to calculate the alternating
stress as: the Stress intensity (P1 -
P3), the equivalent stress (von
 Mises), or the maximum absolute
principal stress (P1).

Stress Range Stress = (σmax - σmin)

Mean Stress Mean stress = Sm = (σmax + σmin)/2

Stress Ratio Stress ratio R = σmin/σmax

Fatigue Life Fatigue life, at a given alternating stress level and mean stress, is
the number of cycles required to cause failure due to fatigue.

Infinite Life Number of cycles where the fatigue strength ceases to decrease. In
other words, the number of stress cycles required to cause failure is
practically infinite.

Fatigue Strength The stress at which fatigue failure occurs after a given number of
loading cycles.

Stress- Life Cycle (S-N) Curve

Fatigue strength is determined by applying different levels of cyclic stress to individual test specimens and measuring the
number of cycles to failure. The graphical representation of fatigue data points is the cyclic stress amplitude or alternating
stress (S - vertical axis) versus the number of cycles to failure (N - horizontal axis). Fatigue strength is defined as the stress at
which fatigue failure occurs at a given number of cycles. A typical S-N curve is shown below.

Usually the base 10 logarithm of number of cycles N is used instead of N due to the typical large range of N
values. In SolidWorks Simulation, you can choose from three interpolation schemes to locate intermediate
data points on an S-N curve: Log-Log, Semi-Log, and Linear. For examples of SN Interpolation schemes, see
SolidWorks Simulation Help: Example of SN Interpolation Schemes.

Specimens are tested in a series of decreasing stress levels until no failure occurs within a selected maximum number of
cycles (usually 10 million cycles). The nearly horizontal portion of the curve defines the fatigue or endurance limit for the test
material. If the applied stress amplitude is below the endurance limit of the material, the specimen is said to have an infinite
life. For many non-ferrous metals and alloys such as aluminum, magnesium, and copper alloys, however, there will not be a
definite endurance limit and the low stress portion of the curve will not converge to a horizontal line. These materials instead
display a continuously decreasing S-N curve.

An S-N curve for a material defines cyclic stress amplitudes (or alternating stress) versus the number of cycles required to
cause failure at a given stress ratio R. Stress ratio R is defined as the ratio of the minimum cyclic stress over the maximum
cyclic stress. For a fully reversed loading, R = -1. When the loading is applied and removed (not reversed), R=0.

Fully-reversed Load, R = -1 Zero-based Load, R = 0

Experimental results have shown that the mean stress has a significant impact on the fatigue resistance of a specimen. For
any material, you can define multiple S-N curves (up to ten) where each S-N curve corresponds to a different stress ratio R.
The software then uses linear interpolation between the S-N curves to extract data for a given stress ratio.
When one S-N curve with stress ratio R = -1 (fully-reversible or zero-mean stress) is used to define the
fatigue properties of a material, you can select a correction method (Goodman, Gerber, or Soderberg) to
account for the effects of non-zero mean stresses.

S-N curves are based on mean fatigue life or a given probability of failure. Generating an S-N curve for a material requires
many tests to statistically vary the alternating stress, mean stress (or stress ratio), and count the number of cycles to failure.

Tests to generate S-N curves are performed under a controlled loading environment. In most cases, the S-N curves are
obtained from uniaxial loading on fully-reversed stress cycles. Since the actual loading environment is generally multi-axial,
you may need to reduce the fatigue strength. The software provides the Fatigue strength reduction factor in the Fatigue
dialog box to account for this discrepancy.

Associating S-N Curves to a Material

To solve a fatigue study, you need to define S-N curves for each material applied to your model. You can enter alternating
stress - cycle data to define a new S-N curve, or you can use an existing S-N curve from the material database. S-N curves
are only used for fatigue studies.
 Some materials in the material library have S-N curves already assigned. These material are identified by an
(SN) suffix at the end of their names in the list box. The reference of the SN curves is the Atlas of Fatigue
Curves, ASM International.
Materials with stress-strain curves are identified by (SS), and materials with both SN curves and stress-strain
curves are identified by (SS,SN).

To assign an S-N curve to a material:

1. In a Fatigue study, add a fatigue event.
2. In the Material dialog, on the Fatigue SN Curves tab, in the Source box do the following:

1. For Interpolate, set the scheme for interpolating alternating stresses against the number of cycles of the S-N curve.

2. Select Define and select a curve from the list. Curves that are already defined have the stress ratio value attached to their
names (for example R = -1). Curves that are not defined are tagged as (Not Defined). Select an undefined curve to populate
with data.

You can define up to 10 S-N curves for different values of stress ratios R to a specific material.
3. In the Table data box, do the following:

1. In the Stress ratio (R) box, enter the stress ratio associated with the curve.

Stress Ratio R = Smin / Smax, where Smin is the minimum stress in the stress cycle and Smax is the
maximum stress.

Mean Stress Smean= (Smax + Smin) / 2

2. Set the unit of stress.

3. Populate the curve data by entering Alternating Stress values versus number of cycles to failure due to fatigue, or click File to
import data from the Simulation S-N Curve library.

To import curve data points stored in a (*.dat) file, click File in the Function Curves dialog.The format of the curve data
points File (*.dat) should have two columns: Number of Cycles (first column) and Alternating Stress (second column).

To add a new row, double-click the last cell under the Points column.

To delete a row, highlight it and click the Delete key or right-click it and select Delete.

4. Click View to graph the data or Save to save the curve to a data file (*.dat).

Preview box shows the curve as it is defined.

5. Type a source of reference for the SN curve data in Source.

4. Click Apply.

Interpolation between S-N Curves

When an S-N curve for a specific stress ratio is not available, the program linearly interpolates between S-N curves to extract
data for a specific stress ratio.

Suppose you have defined only two S-N curves in the material database for a given material for stress ratios 0.5 and 1.0.
Based on your analysis, you want to calculate the number of cycles N for stress ratios 0.25 and 0.7.

The program interpolates linearly between the S-N curves defined for specific stress ratios, if the calculated stress ratio falls in
the range of the defined stress ratios. For example, for the calculated stress ratio of 0.7, the program calculates N1 from the
first curve and N2 from the second curve. It interpolates linearly between N1 and N2 to find the number of cycles N for stress
ratio 0.7.
It the stress ratio falls outside the range of the given S-N curve stress ratios, then the S-N curve with the closest stress ratio is
considered. In the above example, the stress ratio 0.25 falls outside the range of the defined ratio 0.5 to 1.0. The S-N curve
with the closest stress range is 0.5, and therefore, the first curve is considered in the computation of the number of cycles.
In the absence of multiple S-N curves for a specific material, you can use a single S-N curve with a stress
ratio of -1 (zero-mean stress ratio). To adjust the value from the zero-mean stress ratio curve to the actual
intended stress ratio (calculated from the actual stress conditions, apply one of the mean stress correction
methods (Goodman, Gerber, or Soderberg).

Mean Stress Correction

The alternating stress amplitude for a stress cycle is computed as half the stress range in the cycle. The amount of damage
caused by a stress cycle depends not only on the alternating stress but also on the mean stress. For example, the two cycles
below have the same alternating stress but because they have different mean stresses, they cause different amounts of
damage.

The effect of mean stresses on the cycles to failure is illustrated by the following diagram, called the Haigh diagram.

The mean stress is zero only when the load is fully reversible. The most straightforward case is when an S-N curve with the
same R-ratio as the loading is provided. In this case, the S-N curve is directly used since no correction is needed. If you define
S-N curves with different R-ratios, the software accounts for the mean stress by linear interpolation between the curves. If only
one S-N curve with an R-ratio that is different from the R-ratio of the loading is provided, a correction is needed.
The program always uses the von Mises stress to calculate the mean stress. Since von Mises is a positive
quantity, the program assigns the sign of the first mean principal stress to it for the purpose of calculating the
associated mean stress.

Definitions
To discuss correction methods, let us define the following variables for a stress cycle:

Smax = maximum stress

Smin = minimum stress

ΔS = stress range = Smax - Smin

Sa = alternating stress = (Smax - Smin)/2

Smean = mean stress = (Smax + Smin)/2

R = Stress ratio = Smin/Smáx

A = amplitude ratio = Sa/Smean

The stress and amplitude ratios for some common loadings are listed:

Loading Type Stress and Amplitude Ratios

Fully reversed R = -1, A = infinity

Zero to maximum R = 0, A = 1

Zero to Minimum R = infinity, A = -1

Correction Methods
In the following let:

Sca = the corrected alternating stress (based on zero mean.),

Sy = yield stress, and

Su = ultimate strength
The software offers the following methods to calculate S ca:

Method Equation

1. Goodman method- generally suitable for brittle materials:

2. Gerber method - generally suitable for ductile materials

3. Soderberg method - generally the most conservative

 For both variable and constant amplitude events, the software calculates the mean stress in addition to the alternating stress
for each cycle and then it evaluates the corrected stress using the specified criteria.

Performing Fatigue Analysis

To perform fatigue analysis:

1. Create one or more static, nonlinear or modal time history dynamic studies.

2. Create a fatigue study (constant amplitude or variable amplitude) and define its properties. Make sure to set the proper
options before running the study.

3. Notice the events type shown with the name of the Loading folder in the Simulation study tree. Right-click the Loading folder
and select Add Event to define a fatigue event based on a reference static study, or on a particular solution step from a
nonlinear or modal time history dynamic study. To define a fatigue event based on multiple reference studies, set Loading
Type to Find Cycle Peaks.

Variable amplitude events usually contain large amount of data. The Function Curve dialog lets you import text files containing
the data as load history curves. The data become available when defining a variable amplitude fatigue event.

4. You must define at least one SN curve for each material. Click the Fatigue SN Curves tab in the Material dialog box to define
SN curves.

5. Right-click Result options and select Define/Edit to request results at all nodes or at boundary nodes only. If the study is
based on variable amplitude events, you can request the Rainflow matrix chart at the desired locations.

6. For variable-amplitude fatigue studies, right-click a fatigue event icon and select Plot 3D Rainflow matrix or Plot 2D rainflow
matrix to plot a chart for the bins of the input load history

7. Run the fatigue study.

If the results of a reference study, used in defining an event, are not available, the program runs the reference study
automatically before running the fatigue study.

8. Set the fatigue study analysis options. Right-click the topic icon and click Properties. See help topic Fatigue Analysis Options
for more information on the fatigue options.

9. View results:

 Double-click an icon in a results folder to display the associated plot.

 To define a plot, right-click the Results folder and select the Define Fatigue Plot.
 To list results, right-click the Results folder and select List Fatigue Results.
 For studies with variable amplitude events, right-click the Results folder and select Define Matrix Charts to view Matrix
Charts.

Click here for more result viewing options.

If you run a study before meshing it, the program meshes the study automatically before running it. You can also request to
run the study by checking Run analysis after meshing in the Mesh PropertyManager.
When you run a study that does not have any result folders, the software creates the folders and plots specified in the Result
Options for the study type. If result folders are present, the software updates the existing plots.
Fatigue Events

The software handles two different types of fatigue events: constant amplitude and variable amplitude.

You can also define multiple fatigue events, and set the type of interaction between them to: no interaction or random
interaction between events. The random interaction method is based on the ASME Boiler and Pressure Vessel Code. The
software mixes peak stresses from different events to evaluate the alternating stress.

Constant Amplitude Events

All cycles of a constant amplitude event have the same alternating and mean stresses. A constant amplitude fatigue event is
fully defined by an alternating stress, mean stress (or stress ratio), and the number of cycles.
A fatigue event can be based on:
A single load case from a static study, or from a particular solution step of a nonlinear or modal time history dynamic study.
Multiple load cases from static studies or from solution steps of a nonlinear or modal time history dynamic studies. In the case
of multiple load cases, the software determines the load case combination that produces the largest stress fluctuation.

Example of Constant Amplitude

Event

Variable Amplitude Events

A variable amplitude fatigue event is a load history record that defines the fluctuation history of a load. The time values do not
play any role for fatigue studies with a single variable amplitude event. In this case, it is adequate to define the amplitude
sequence. For studies with more than one variable amplitude fatigue events, time values are needed for each record to
correlate to other loading events.

Number of Repeats
 Add Event (Constant) PropertyManager
The Add Event (Constant) PropertyManager allows you to define a constant
amplitude event for a fatigue study.

You can set up a fatigue event based on a single load case or several load cases
from multiple reference studies. The fatigue loads can refer to one or more static
studies, or to a particular solution step of a nonlinear or time history linear dynamic
study.

Load

No. of Cycles Sets the number of cycles associated with

this event.

Loading Type Sets the type of fatigue loading to determine the stress peaks and hence the alternating stress. Alternating
stress = |maximum stress - minimum stress|/2, where | | denotes the absolute value.

Fully reversed (LR = -1) The fatigue event is based on one reference study. All loads, and hence stress
components, in the reference study change their magnitudes proportionally from
their maximum values as specified by the reference study to zero.

Zero-based (LR = 0). The fatigue event is based on one reference study. All loads, and hence stress
components, in the reference study change their magnitudes proportionally from
their maximum values as specified by the reference study to zero.
 Loading ratio The fatigue event is based on one reference study. Each load, and hence each
stress component, in the reference study changes its magnitude proportionally
from its maximum value (Smax) to a minimum value defined by R*Smax, where R is
the load ratio. A negative ratio indicates reversal of the load direction.

Loading ratio . Enter a loading ratio.

Fatigue loads are said to be proportional when the directions of principal stresses
for each node are identical for all the reference studies that you use in defining
fatigue events. In all other cases, the fatigue loads are said to be non-proportional.

Find Cycle Peaks The fatigue event is based on several load cases. The program calculates the
alternating stresses for each node by considering the combination of peaks
from different fatigue loads. It then determines the combination of loads that
produces the largest stress fluctuation.

The fatigue loads can refer to one or more static studies, or to a particular
solution step of a nonlinear or linear dynamic time history study.

Study Sets the reference studies.

Association
No. Study counter.

Select Find cycle peaks to continue defining up to 40 load cases. Double-click in the No. cell to add a row.
All studies must have the same mesh.

Study. Sets the reference study. Click in this cell to select a study from the drop-down menu. For a references
study, you can select a static study, or stress results from a particular solution step of a nonlinear or linear
dynamic study.
The list of studies includes the studies that are associated with the currently active
configuration only.

Scale. This scale factor lets you define a fatigue event based on a reference study with scaled loads. Since the
study is linear, the program uses this factor to scale the stresses. You cannot scale loads defined in a
nonlinear study.

For example, if the reference study has a pressure load of 50 psi applied to a face and you want to define a
fatigue load based on 150 psi on the same face, you should enter a scale factor of 150/50 = 3. The program
multiplies the stress results of the reference study by this factor to calculate stress values for use in
calculating alternating stresses.
 Step. Sets the solution step for the reference nonlinear or linear dynamic study. The program uses the stress
results of this particular step to calculate the alternating stresses.

You can use the same study for defining multiple fatigue events.

Defining a Fatigue Event Based on a Single

Load
To define a fatigue event based on a single load case, in the Add Event (Constant) PropertyManager:

1. Set the Number of Cycles associated with the fatigue event.

2. From the Loading Type menu , choose one of the following options:
 Fully reversed
 Zero based
 Load ratio

3. In the Study Association box :

1. Select a static, nonlinear or dynamic time history study in the first row. You can enter a scale factor under Scale. The program
multiplies the stress components of the reference study by this factor to evaluate alternating stress values.
2. For a nonlinear or dynamic time history study, under Step enter a particular time step. The output of this particular solution
step is considered for the evaluation of alternating stress values.

4. Click .

Single Constant Amplitude Fatigue Event

A constant amplitude fatigue event is fully defined by an alternating stress, mean stress (or stress ratio), and the number of
loading cycles.

Fully reversed The program sets the alternating stress at each node equal to the selected
stress value (stress intensity, von Mises, or P1) from the reference static
study times the scale factor. The maximum and minimum values of stress
components are equal in magnitude and opposite in direction.

Zero-based The program sets the alternating stress at each node equal to half the
corresponding stress value in the reference static study times the scale
factor. The program gets one of the peaks from the reference static study
and sets the other peak to 0.
 User-defined load Assuming that the user-defined load ratio is R, the program gets one of the
ratio peaks from the reference study (considering specified scale factor) and
calculates the other peak by multiplying the first peak by R. The program
then calculates the stress quantity selected in the Fatigue properties dialog
box and calculates the alternating stress as |S*(1 - R)|/2 where S is the
extreme value of the stress component in the reference static study.

Defining a Fatigue Event Based on Multiple

Load Cases
To define a constant amplitude fatigue event based on multiple load cases, in the Add Event (Constant)
PropertyManager:

1. Set the Number of Cycles associated with the fatigue event.

2. Set Loading Type to Find Cycle Peaks .

3. In the Study Association box :

1. Select a static, nonlinear or dynamic time history study in the first row. You can enter a scale factor under Scale. The program
multiplies the stress components of the reference study by this factor to evaluate alternating stress values.
2. For a nonlinear or dynamic time history study, under Step enter a particular time step. The output of this particular solution
step is considered for the evaluation of alternating stress values.
4. Insert a new row by double-clicking in the No column. Select a study and enter a scale factor. You can enter up to 40 load
cases.

5. Click .
The program evaluates at each node the differences in the stress component values for all possible
combinations of stress peaks and determines the load combination that produces the largest stress
fluctuation.

Single Fatigue Event Based on Multiple Loads

The program calculates the alternating stresses for each node by considering the combination of peaks from different fatigue
loads. The fatigue loads can refer to one or more static studies, or to a particular solution step of a nonlinear or time history
linear dynamic study.

To set up a fatigue event based on multiple load cases, select Find Cycle Peaks (Add Event (Constant) PropertyManager).
You can define up to 40 load cases.

Suppose that you specified fatigue loads using studies A, B, and C with scale factors FA, FB, and FC to define an event. In order
to evaluate the alternating stress and the associated stress ratio at a node, the program proceeds as follows:
It evaluates SA*FA, SB*FB, and SC*FC, where SA, SB, and SC refer to the stress component values at the node for studies A, B,
and C, respectively. The program calculates the SX, SY, SZ, TXY, TXZ, and TYZ stress components at each node.
Evaluates the differences in the stress component values for all possible combinations of stress peaks and determines the
combination that produces the largest stress fluctuation.
Evaluates the alternating stress associated with the event by dividing the stress fluctuation range by 2.
Calculates the stress ratio based on the calculated stress extremes (Smin and Smax).
If multiple S-N curves with different stress ratios are defined, the program uses linear interpolation to extract the proper
number of cycles for the calculated alternating stress and stress ratio.
If a single S-N curve with zero mean is defined and a mean stress correction method is selected, the program uses the
corrected alternating stress against the S-N curve.

Add Event (Variable) PropertyManager

The Add Event (Variable) PropertyManager allows you to define a variable amplitude event for a fatigue study. You can define
multiple fatigue events for one fatigue study. A variable amplitude fatigue event refers to one or more static studies, or to a
particular solution step of a nonlinear or time history linear dynamic study.

Load

Get Curve Opens the Load History Curve dialog to define the curve data. You can define the curve
manually or load a predefined history.
The Simulation Curve library includes sample Load History curves from SAE.

View Graphs the load history curve.

Study Sets the reference static study.

Association
 No. Study counter. Only one study is allowed for each variable amplitude event.

Study. Click in this cell to select a study from the drop-down menu. The list of studies includes the
studies that are associated with the currently active configuration only.
The program uses linear theory. Scaling results is invalid if the static study
includes nonlinear effects such as contact or large displacements.

Scale. Use this scale factor to relate the amplitudes of the variable load history curve to the load in
the study. You cannot scale loads defined in a nonlinear study.

For example if the amplitudes are measured in volts, the scale factor must relate volts to the
load unit.

If the model is subjected to multiple loads, define multiple studies with one load in each
study. You can then define one event for each load case with the proper scale factor.

Option

Number of Repeats the curve data the specified number of times.

Repeats.
Example:

No. of Repeats = 1 No. of Repeats = 3

Event Start
Time. Use this entry to time the selected multiple events. This input is ignored if you define a single event
for the study.
Example:

Event start time = 0 Event start time = 50

 Theory of Cumulative Damage

The theory of cumulative damage assumes that a stress cycle with an alternating stress above the endurance limit inflicts a
measurable permanent damage. It also assumes that the total damage caused by a number of stress cycles is equal to the
summation of damages caused by the individual stress cycles.

Linear Damage Rule

Assume that the S-N curve indicates that it takes N1 cycles at an alternating stress S1 to cause fatigue failure, then the theory
states that each cycle causes a damage factor D1 that consumes 1/N1 of the life of the structure.

Moreover, if a structure is subjected to n1 cycles at S1 alternating stress and n2 cycles at S2 alternating stress, then the total
damage factor D is calculated as:

D = (n1/N1 + n2/N2),

where N1 is the number of cycles required to cause failure under S1, and

N2 is the number of cycles required to cause failure under S2.

This rule is referred to as the Linear Damage Rule or the Miner's Rule. The damage factor, also called usage factor,
represents the ratio of the consumed life of the structure. A damage factor of 0.35 means that 35% of the structure's life is
consumed. Failure due to fatigue occurs when the damage factor reaches 1.0.

The linear damage rule does not consider the effects of load sequence. In other words, it predicts that the damage caused by
a stress cycle is independent of where it occurs in the load history. It also assumes that the rate of damage accumulation is
independent of the stress level. Observed behavior indicates that cracks initiate in a few cycles at high stress amplitudes,
whereas almost all the life is spent on initiating the cracks at low stress amplitudes.

The linear damage rule is used in its simple form when you specify that fatigue events do not interact with each other in the
properties of the study. When you set the interaction between events to random, the program uses the ASME code to
evaluate the damage by combining event peaks.

Multiple Fatigue Events

Evaluating alternating stresses for multiple fatigue events depends on whether the events occur randomly or independently
(no interaction between events). You can set the type of interaction between multiple fatigue events in the Fatigue dialog box.

No Interaction SolidWorks Simulation evaluates the alternating stress separately for each
event. Each fatigue event occurs independently from the other events. The
damage factors from all events are added sequentially.

Random Interaction The software considers the possibility of mixing peak stresses from
different events for the evaluation of alternating stresses.

The software evaluates the maximum alternating stress by considering all possible
pairs of fatigue events at each node. It then uses the Miner’s rule and the ASME Boiler
and Pressure Vessel Code to define a set of modified fatigue events.

The random interaction between events option predicts a higher damage factor than applying the defined
events sequentially, unless the stress peaks from different events are marginally different. In such cases, it is
recommended to run two fatigue studies; one study with no interaction between events and the other study
with random interaction. The results can reveal that one option gives higher damage at some locations while
the other option gives higher damage at other locations.
Random Interaction between Multiple Fatigue
Events

The Simulation application mixes peak stresses from different events to evaluate alternating stresses.

Suppose you specified three fatigue events that reference studies A, B, and C using scale factors Fa, Fb, and Fc. The software
calculates the alternating stresses and damage factors as follows:
For the three reference studies, the software computes the state of stress at each node scaled by the associated factors: Sa *
Fa, Sb* Fb, Sc*Fc

, where Sa, Sb, and Sc refer to the stress component values [SX, SY, SZ, TXY, TXZ, TYZ] at a node for studies A, B, and C,
respectively.
For all possible pairs of load combinations, the software subtracts the six stress components of one load case from the
corresponding components of the second load case to yield the component stress range. For n number of loadings, the
possible load combinations are (n * (n -1) / 2).
For each component stress range, the software calculates the alternating stress as one-half of the selected quantity (stress
intensity, von Mises, or maximum absolute principal). The software creates a list of the alternating stresses with the
corresponding loading pairs for all possible combinations in decreasing order.
Based on the selected fatigue curve (S-N curve), the software checks the alternating stress list from the highest value to the
lowest value.

The software evaluates the partial damage factor Di for the ith alternating stress in that list by evaluating the cycle ratio ni / Ni
(ni is the lower number of cycles remaining from either events; Ni is the allowable number of cycles interpolated from the
design fatigue S-N curve.
After evaluating the partial damage factor, Di, the software updates the alternating stress list by reducing the number of cycles
of both events by ni. Consequently, one of the two events will be eliminated (or both if they 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 loading. Once a loading is eliminated, the corresponding alternating stress (formed by combining that loading
with other loadings) is also eliminated from the list.
After updating the list, the software checks the next alternating stress in the list and evaluates the corresponding partial
damage factor, adds that to the cumulative one, and updates the list. This procedure is repeated for the next alternating stress
in the list and continues until all stress values are considered.

Example of Random Interaction for Constant

Amplitude Fatigue Events

When you select Random interaction, the software mixes peak stresses from different events to evaluate the alternating
stress.

Different loading events can interact in such a way that the maximum positive peak stress from one event combined with the
minimum peak stress from another event produces a larger alternating stress than either one of the fatigue events.

The Random interaction option predicts a higher fatigue damage factor than applying the different fatigue events sequentially
(No Interaction). The Random interaction method is based on the ASME Boiler and Pressure Vessel Code.
For example, consider these three events:

Event 1 Event 2 Event 3

Number of cycles 80,000 230,000 120,000

Min Stress 0 -300 MPa 0

Max Stress 500 MPa 0 200 Mpa

If Random interaction is considered, the sequence of events that results in the largest stress variation is when one cycle of
Event 2 proceeds each cycle of Event 1. In this case the stress fluctuates from 500 MPa (max stress of Event 1) to -300 MPa
(min stress of Event 2), resulting in a 800 MPa stress variation (alternating stress is 400 MPa and average stress is 100 MPa).

Since there are only 80,000 cycles of Event 1, this sequence of events can happen only 80,000 times. After the first sequence
of events, there are only 150,000 (= 230,000 - 80,000) cycles remaining of Event 2.

For the next event sequence, let's assume that one cycle of Event 3 proceeds each of the remaining cycles of Event 2,
resulting in a stress variation of 500 MPa (alternating stress of 250 MPa and an average stress of -50 MPa).

Since there are only 120,000 cycles of Event 3, the second sequence of events can happen 120,000 times.

Finally, 30,000 cycles of Event 2 are left. This corresponds to an alternating stress of 150 MPa, with an average stress of -150
MPa.

Random Interaction

Event 1 followed by Event 2 80,000 cycles of a 400 MPa alternating stress with an average stress of 100
MPa

Event 2 followed by Event 3 120,000 cycles of a 250 MPa alternating stress with an average stress of -50
MPa

Event 2 30,000 cycles of a 150 MPa alternating stress with an average stress of -150
MPa

No Interaction

Event 1 80,000 cycles of a 250 MPa alternating stress with an average stress of 250
MPa

Event 2 230,000 cycles of a 150 MPa alternating stress with an average stress of -
150 MPa

Event 3 120,000 cycles of a 100 MPa alternating stress with an average stress of 100
MPa

For studies with fatigue events referencing multiple studies, the program calculates peak stresses based on the Random
Interaction option even if you select the No interaction option.
The ASME Boiler and Pressure Vessel code recommends using the Random Interaction option. It is generally more
conservative (predicts higher damage) than the No interaction option.
 Rainflow Cycle Counting Method

The Rainflow cycle counting method extracts the composition of a variable amplitude load history. The software implements
the method as follows:
1. Extract peaks and troughs from the load history.
2. Make the amplitudes of the first and last data points the same by appending a data point if necessary.
3. Detect the highest peak and reorder the data such that the highest peak becomes the first and last points.
4. Start counting the peaks as follows:
1. Consider the first four peaks and troughs ( 1, 2, 3, and 4). A Rainflow cycle is counted if the second segment is vertically
shorter than the first and the third segments (i.e. b is smaller than a and c).

2. If a cycle is counted, the program starts from the beginning of the record ignoring peaks that have already been counted. If no
peak is counted, the program checks the next group of peaks (peaks 2, 3, 4, and 5) and the process continues. At the end,
each peak and each trough corresponds to a Rainflow cycle.
3. Ignore and load cycles that are below the percentage specified in the properties of the study.
4. Divide the alternating and mean stress ranges into the number of bins specified in the properties of the study. You can view
the results by viewing the Rainflow matrix chart.
5.

Application of the Rainflow Cycle Counting Method

Fast Fast counting is used when the fatigue study refers to one static study and has only one variable-
Counting
amplitude event. In this case, the program extracts bins directly from the original record. It then
evaluates the damage resulting from each bin at each node and calculates the accumulative damage.

Full When multiple variable-amplitude events are used, the program calculates the stresses at each point in time for each
Analysis
variable-amplitude record at every node. At each node, the program combines the stresses and extracts the Rainflow
bins that are then used to evaluate the damage.

Full analysis is also used when a variable amplitude record is associated with more than one study with the different
shifts or intervals.
Fatigue Plots

After you perform a fatigue analysis, you can plot life, damage and factor of safety plots for the model.

Suppose you run a static analysis and define a fatigue study with the static analysis being the only event that occurs N times.
Consider the S-N curve for the material as shown:

The program, based on the loading ratio, determines a corrected alternating stress from the static study's stress value for each
node.
In the graph above, the green dot represents the alternating stress (Y coordinate) and number of cycles for
which the event occurs (X coordinate) for one node. One out of three possible outcomes can occur for each
node:
The dot lies above the curve. Fatigue failure is predicted at that location.
The dot lies below the curve. Fatigue failure does not occur at that location.
The dot lies outside the range of S-N curve. The highest corrected alternating stress in the model must be within the stress
range of the S-N curve. Also, the number of cycles (N) should be within the cycle range of the S-N curve. Otherwise, instead
of an intersection point, the program uses the S-N curve's end point.

To simplify the discussion, we did not consider the scenarios where multiple S-N curves for a material and
several events are defined.

This table describes Life, Damage, and Factor of Safety.

Fatigue Description Relation Notes

Plots

Life The number of cycles that Life = N - ΔN Life plot is available only when you define a single
causes failure at a model event.
location. In the graph it is Life value depends only on the stress value at a
the intersection between the location and the S-N curve. It does not depend on
horizontal line for σ and the the number of fatigue cycles.
S-N curve. If the corrected alternating stress in the model falls
below the stress level of the last point of the S-N curve,
the program takes the number of cycles defined for the
last point of S-N curve, unless you define and select the
Infinite Life option in the fatigue study's Properties, in
which case the Infinite Life will be taken to calculate
the Damage.
If the event is Variable Amplitude of Constant
Amplitude), then the Life results given by the fatigue
analysis are in terms of blocks instead of cycles, where
blocks are defined as the total load history (including
the number of repeats of the event in the curve)
specified by the user.
 Fatigue Description Relation Notes
Plots

Damage The percentage cumulative Damage = N/(N - ΔN) A value of 1 indicates that the defined fatigue
damage factor or the events consume 100% of the model life at that
percentage life consumed. location.

Factor of The ratio of the stress value FOS = (σ-Δσ)/σ The FOS plot is available only when a single
Safety that causes fatigue failure event is defined in the fatigue study.
over the stress σ. A factor of safety of 2.0 at a location predicts
failure at that location when applied loads are
multiplied by 2.0.

Fatigue Result Options PropertyManager

The Result Options PropertyManager allows you to set options for the results of fatigue studies.

Fatigue Calculations
Requests damage calculations at all nodes or boundary nodes.

Whole model Calculates damage at all locations (nodes) of the model. In an assembly, cracks can
occur inside the model at the interface of two parts with different materials. In most
other cases, cracks occur at the model boundary.

Surface only Calculates damage at boundary nodes only. Using this option saves time since less
calculations are needed. The savings are substantial for large problems with multiple
variable amplitude fatigue loading.

Matrix Chart Locations

Sets the locations (vertices and reference points) at which you can plot the Rainflow matrix chart.

Fatigue Check Plot

Available in SolidWorks Simulation Professional and SolidWorks Simulation Premium.

CONTENTS
Defining a Fatigue Check Plot

The Fatigue Check Plot alerts you if certain regions of your model are likely to fail due to repeated loading and unloading
over infinite time. If regions of your model are shown in red, you should set up a Fatigue study.

Fatigue Check Plot PropertyManager

The Fatigue Check Plot alerts you if certain regions of your model are likely to fail due to repeated loading and unloading
over infinite time. The plot is based on a single constant-amplitude fatigue event with a fully-reversible or zero-based loading.

Fatigue Check Plot Calculations

The blue and red regions of the fatigue check plot are determined from the diagram below. For each node, the program
calculates the alternating and mean stresses based on the defined fatigue event type.
 Defining a Fatigue Check Plot

The Fatigue Check Plot alerts you if certain regions of your model are likely to fail due to repeated loading and unloading
over infinite time. If regions of your model are shown in red, you should set up a Fatigue study.

1. Set up a Static study with the appropriate material, contact conditions, loads and fixtures.

Allowable mesh types are: solid, shell, and mixed mesh with surface and solid bodies.

2. After you run the study, in the Simulation study tree, right-click Results , and select Define Fatigue Check Plot.

3. In the PropertyManager:

1. Under Bodies to Check, select one or all bodies.

2. Under Modifying Factors, select the Loading type.
3. Type the reduction factors for the fatigue strength of the selected bodies, or select Specify to set a cumulative reduction
factor.

In the graphics area, regions of the model that are safe from fatigue failure are blue, and regions that are likely to fail due to
fatigue are red.
You can also modify the fatigue strength and rerun the fatigue check plot module. Under Material, type a scale factor between
1 to 5 to increase it, or a safety factor between 1 to 5 to reduce it. Click in the graphics area to update the fatigue check plot.

Fatigue Check Plot PropertyManager

The Fatigue Check Plot alerts you if certain regions of your model are likely to fail due to repeated loading and unloading
over infinite time. The plot is based on a single constant-amplitude fatigue event with a fully-reversible or zero-based loading.

To display this PropertyManager, run a static study. Right-click Results and select Define Fatigue Check Plot. You need a
Simulation Professional or Simulation Premium license to see this option.
The Fatigue Check plot is not available for composite shells or beams.

Bodies to Check

Select all bodies Enables selection of all bodies in your model.

Select body Selects the body to include in the Fatigue

Check Plot.

Modifying Factors
Apply the reduction factors to the fatigue strength of the selected bodies. Once the reduction factors are determined, the
fatigue strength, FS(component), of the selected components in their working condition is evaluated as:

FS(component) = FS(material) x Surface Finish Factor x Loading Factor x Size Factor

The material fatigue strength, FS(material) , equals half the material's tensile strength.

Loading type Applies zero-based fatigue loading to determine the mean and alternating stresses.

Mean stress = Alternating stress = ½ * max [P1 or (P1-P3)/2)]

 Applies fully-reversed fatigue loading to determine the mean and alternating stresses.

Mean stress = 0

Alternating stress = max [P1 or (P1-P3)/2]

P1,P2, P3 are the first, second, and third principal stresses, respectively.

Calculate Specifies the fatigue strength reduction factors.

Surface Finish Specifies the correction surface finish factor. A surface finish correction allows
Factor the estimate of the fatigue strength of the part in its working condition. Select
an appropriate surface finish type from the list or select Other to enter a user-
defined value. The range is from 0.1 to 1.

Loading Factor Specifies the correction loading factor. Fatigue limits are usually determined
from test specimens under bending. A specimen loaded in tension has a lower
fatigue limit. Select a loading type from the list, or select Other to enter a
user-defined value. The range is from 0.1 to 1.

Size Factor Specifies the correction sizing factor. Based on experimental results, larger
parts have lower fatigue limits than smaller parts. The range is from 0.1 to 1.

Specify Sets the fatigue strength cumulative reduction factor which is equal to:

Surface Finish Factor x Loading Factor x Size Factor

The range is from 0.001 to 1.

Material
The material description and fatigue strength are shown when you select a single body. The fatigue check plot calculations are
performed, and you are notified if your model is susceptible to fatigue failure.

A green icon indicates that the model is safe, and will not fail under repeated cycles of loading. All selected bodies appear
blue in the graphics area.
A red icon alerts you that parts of your model could fail due to cycling loading. The regions of your model that
are susceptible to fatigue are shown in red. Run a Fatigue study to access the safety of your design in more
details.

Scale all fatigue Multiplies the fatigue strength of the selected components by the given factor.
strength The range is from 1 to 100.

Minimum safety Divides the fatigue strength of the selected components by the given safety
factor factor. The range is from 1 to 10.

The modified fatigue strength of the component is:

Modified fatigue strength = FS(component) * Scale factor / Safety factor

Type a scale factor or safety factor larger than 1 and click in the graphics area. The fatigue check plot is calculated and the
color of the the selected components is updated in the graphics area.

Fatigue Check Plot Calculations

The blue and red regions of the fatigue check plot are determined from the diagram below. For each node, the program
calculates the alternating and mean stresses based on the defined fatigue event type.
FS(m) = Modified material fatigue strength, Sy = Material yield stress, St = Material tensile strength

For a zero-based loading fatigue event , all points are located on the 450 axis with coordinates:

mean stress = alternating stress = ½ * max [P1 or (P1-P3)/2)]

where P1, P2, P3 are the first, second, and third principal stresses, respectively.

Regions of the model with corresponding points in the green region of the diagram are blue in the fatigue check plot, and are
safe from fatigue loading. Regions of the model with points outside the green region are red in the fatigue check plot, and are
susceptible to failure due to fatigue.

For a fully-reversed loading fatigue event , all points are located on the vertical axis (mean stress =0)
with alternating stress = max [P1 or (P1-P3)/2)].

Regions of the model with alternating stress smaller than the modified material fatigue strength FS (M) are blue in the fatigue
check plot, and are safe from fatigue loading. Regions of the model with alternating stress larger than FS(M) are red in the
fatigue check plot, and are susceptible to failure due to fatigue.