PSI - Issue 57

Laurent Dastugue et al. / Procedia Structural Integrity 57 (2024) 355–364 Michael Klein et. al./ Structural Integrity Procedia 00 (2019) 000 – 000

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consumed. The new automatic process reduces the runtime for this industrial example to 22 minutes on an 18 cores computer. In addition, the process is easily transferable to new variants or follow up projects. In this way, the process knowledge is integrated into a method which is transferrable and therefore ensures high reliability for this industrial process. 7. Summary and Outlook The computing time, the amount of data and the effort for the multi-stage process fatigue life analysis with many sources of error are a prevent usage of this type of analysis in industrial applications. The long run times prevent the fatigue life analysis because today’s short product cycles do not have enough time for such long processes. In addition, the classic process, in which all stress data must be temporarily stored, the huge data volumes for the fatigue life analysis of big FEA models prevent usage. The storage capacity is often insufficient even at OEMs. These aspects completely prevent the performance of a fatigue life analysis in industry. The new integrated fatigue life analysis improves the crucial points so significantly that industrial application is possible. In addition, the integration of fatigue life analysis in the FE solver makes the process robust. Integration means, that stress calculation and fatigue life analysis are integrated in one software and do not require any interfaces. Therefore, there are no complications with data management. As an additional advantage the accuracy of the fatigue life analysis is increased through improved accuracy for the stress gradients (chapter 3.2). Run time has been drastically reduced (fig. 15) and the new “On -the- fly” calculation of results (chapter 3.3), without caching, saves the complete disk space which was consumed for intermediate storage for stresses. This removed the show stoppers that prevented industrial use. Basic technology and infrastructure for fatigue analysis in the FE solver is developed. This is the perfect starting point for functional expansion, like extension by further fatigue approaches, optimization with damage as objective functions and design constraints. Integration, process reliability and short run times allow the industrial usage of fatigue optimization and sampling. Acknowledgements Acknowledgements go to all developers at INTES, who have again managed to set new standards in terms of accuracy, process reliability and calculation speed with this functionality. References Bernd, A., Michy, J., Ast, M. Heinemeyer, E., Klein, M., 2022. Reduktion der Prozesskomplexität durch Integration der Lebensdauerberechnung in die FEM-Simulation, VDI SIMVEC, November 22 nd – 23 rd 2022 Bernd, A., Michy, J., Klein, M., 2022. Integrated Fatigue Lifetime Prediction of a Differential Case, PERMAS Web Conference, June 29 th – July 7 th , 2022 Häckh, J., Schünemann, A., 2021. Integrated Fatigue Analysis in PERMAS – Development Preview –, PERMAS Tech Meeting, April 22 nd , 2021 Willmerding, G., Häckh, J., 2019. Fatigue Life estimation using winLIFE and PERMAS, PERMAS Technologietag, April 11 th , 2019