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Hcf/lcf fatigue life calculator for ansys workbench using act/python

Author: 
Dr. Suresh Babu, K. S., Mallikarjuna Hosamath and Rajendra Gai
Subject Area: 
Physical Sciences and Engineering
Abstract: 

The traditional HCF/LCF life evaluation is manual process of recording/probing the alternating stress and mean stress for each node in FEA model, followed by using Goodman diagram to calculate the life. The process is time consuming for evaluating the entire model fatigue life. Automating the manual process in CAE is of utmost importance for error-free calculation, productivity improvement, reliable, and reduced design cycle time. The above objectives were met by developing fatigue life calculator tool. The tool carries out high cycle and low cycle fatigue life calculations based on Goodman failure theory. The fatigue life calculator is automated process of calculating the HCF/LCF life. The tool extracts the stress for all nodes from alternating stress and mean stress FEA models. The tool also supports the solution combination operations for various load case result sets. The ACT extension "HCF/LCF Fatigue Life Calculator" is developed for ANSYS Workbench. The tool is developed using ANSYS Workbench API, XML, Microsoft visual studio VB, and Python. The tool also contains several .NET forms for user information and guidance. The ACT extension creates seven submenus under "Life Calculator" menu. First, The tool extracts the mean stresses and alternating stresses. The tool created ANSYS Workbench journal for mapping the results from harmonic analysis FE model to mean stress FE model i.e., tool supports the different mesh between mean and alternating stress FE models known as location-based evaluation. Then, user choice for solution combination will be taken using additional tool developed in Microsoft visual studio VB application. Once user choice is taken, the ACT extension performs solution combination and fatigue life calculations for entire FE model. The tool also supports the displaying the results in Ansys mechanical. The tool plots the life contour on FE model in ANSYS mechanical.

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