Fatigue analysis - system parameters optimization

Abstract: For a mechanical system exposed to repeated cyclic loads fatigue is one of the most common reasons for the system to fail. However fatigue failure calculations are not that well developed. Often when fatigue calculations are made they are done with standard loads and simplified cases. The fatigue life is the time from start of use until the system fails due to fatigue and there does exist some building blocks to calculate the fatigue life. The aim for this project was to put these building blocks together in a workflow that ca be used for calculations of the fatigue life. The workflow was built so that it should be easy to follow for any type of me- chanical system. The start of the workflow is the load history of the system. This is then converted into a stress history that is used for the calculations of the fatigue life. Finally the workflow was tested with two test cases to see if it was possible to use. In Algoryx Momentum the model for each case was set up and then the load history was extracted for each time step during the simulation. To convert the load history to stress history FEM calculations was needed, this was however not a part of this project so the constants to convert loads to stress was given. Then with the stress history in place it was possible to calculate the fatigue life. The results from both test cases were that it was possible to follow every step of the workflow and by this use the workflow to calculate the fatigue life. The second test also showed that with an optimization the system was improved and this resulted in a longer lifetime. To conclude the workflow seems to work as expected and is quite easy to follow. The result given by using the workflow shows the fatigue life, which was the target for the project. However, to be able to evaluate the workflow fully and understand how well the resluts can be trusted a comparison with empiric data would be needed. Still the results from the tests are that the workflow seem to give reasonable results when calculating fatigue life.