Winter Edition 2005/2006 - No.

1st FEMFAT User Meeting Korea, Seoul

Fifty delegates, including major companies such as Hyundai Motor Co., Tata Daewoo, Katech, Rotem, Doosan Infracore, Jatco, and DongYang Piston, and representatives from the Kangwon, Kyungsang, Donga and Hanseo Universities met on 13 October in the 63 Building in Seoul for the first Korean FEMFAT User Meeting. In addition to the presentation on FEMFAT 4.6 and practical tips, durability exper ts from Doosan Infracore (formerly Daewoo), Rotem and our partner ATES talked about their experiences with FEMFAT.

Many thanks for your continued loyalty.

Happy Christmas!

We attribute the increasing number of Korean users not only to FEMFATs excellent reputation, but also to the exper t sales and

suppor t provided for our products by our sales par tner ATES Advanced Technology Engineering Services.

Durability & Fatigue Meeting, Detroit

crankshaft using NASTRAN, ADAMS and FEMFAT. A relevant workshop example completed each presentation, demonstrating the simplicity and speed of using FEMFAT.

FEMFAT VISUALIZER Evaluation extended

In FEMFAT 4.6, the VISUALIZER module has also been significantly revised, and new features added (stress animation). Numerous improvements in per formance feature alongside high display quality and automatic graphical output. We invite you to tr y out this costeffective tool free for one-month, so that you can see for yourself the benefits of FEMFAT VISUALIZER.

Contents:
1st FEMFAT User Meeting, Korea ___ 1 Durability & Fatigue Meeting, Detroit _______________ 1 Future platform strategy __________ 2 FAQs: When/Why BASIC, ChannelMAX or TransMAX _______________ 3 Isothermal temperature influence ____ 3 FEMFAT star tup options ___ 3 Training courses ________________ 4 News __________________________ 4 Stop press _____________________ 4 Event calendar 2006 ____________ 4 Publishers information __________ 4

Visit our website:

www.femfat.com

Magna Powertrain (MPT) and Altair Engineering held a Fatigue & Durability Meeting in Troy/Detroit on the 21 October. The pleasant surroundings of the Altair Headquarters were used as the venue for presenting the software from both companies and for discussing hot topics in operational strength analysis. MPT and Altair were delighted to welcome some 80 delegates, primarily from the automotive industr y, including DaimlerChr ysler, Ford, Nissan, Detroit Diesel, Toyota, Mazda, Honda, AVL, FEV, Federal Mogul, SMW, Wayne State University, Visteon, McLarren Performance and BASF, to name but a few. The presentations kicked off with a review of the HyperWorks products from Altair, followed by presentations from the FEMFAT team of Helmut Dannbauer, Dietmar Peiskammer and Matthias Meise who described capabilities of the FEMFAT modules in detail and illustrated potential applications. Specialized topics included Stress and fatigue analysis of a cylinder block, Predicting car body fatigue life, "Virtual iteration using MBS and FEMFAT or Modal-based strength analysis of a

During the lively discussion periods, there was a vigorous exchange of views between the delegates. Numerous detailed questions on specific applications linked to FEMFAT were discussed with the local support team in Troy, even days after the meeting. Looking for ward to the second FEMFAT User Meeting North America, which takes place in fall 2006 in Detroit, the FEMFAT team are hoping for numerous user papers. MAGNA POWERTRAIN ALTAIR cooperation: intensive discussions are currently taking place with Altair on the future coupling of FEMFAT in HyperView. On the cards is a preconfigured FEMFAT star tup, in which entity and stress data is imported automatically for example. This can deliver even greater efficiency when working with Altair products.

FEMFATNEWSLETTER
Future platform strategy
In general, all FEMFAT modules will run in future on all supported hardware platforms. Summary of FEMFAT 4.6 hardware platforms AMD Opteron Operating system Linux Linux Linux AIX 5.1L IRIX 6.5.22 HP UX 11.00 HP UX 11.23 Windows XP 64 SUN Solaris Platform i686 Bits Note 32 glibc 2.3 or above, Kernel 2.4 or above Intel Pentium IV SGI Altix HP Itanium2 IBM Power3 Intel Pentium III SGI MIPS HP PA-Risc SUN Sparc Hardware

Winter Edition 2005/2006

Performance comparison for FEMFAT 4.6 Operating system Redhat EL 3 Windows XP Redhat EL 3 HP-UX 11.22 AIX 5.1L Redhat 7.3 IRIX 6.5 HP UX 11.00 Solaris 8 CPU speed [Mhz] 2000 3400 1400 900 450 800 400 360 333

Opteron, 64 glibc 2.3 or above, AMD64, EM64T Kernel 2.6 Itanium2 Power3/4 MIPS PA-Risc 2.0 Itanium2 64 glibc 2.3 or above, Kernel 2.4 or above 64 32 64 HP Quality Pack required 64 32 SP3 required

Windows 2000/XP i686

Opteron, 64 planned release AMD64, EM64T spring 2006 Sparc 32

Computing time normalized to AMD Opteron Summary of FEMFAT 4.6 interfaces All binary interfaces automatically support big/little endian conversion (data transfer PC <-> workstation). Linux, Opteron, AMD64, EM64T Windows XP64, AMD64, EM64T
AMD Opteron Intel Pentium IV SGI Altix HP Itanium2 IBM Power3

HP UX 11.00, PA-Risc 2.0

HP UX 11.23, Itanium2

Windows 2000/XP, i686

AIX 5.1L, Power 3/4

SUN 32 Solaris, Sparc

Intel Pentium III SGI MIPS HP PA-Risc SUN Sparc

Interface Abaqus fil Abaqus odb Ansys cdb Ansys geo Ansys lis Ansys rst Cosmos I-DEAS universal Indeed Intergraph LS-Dyna d3plot Marc t16 Medina bif/bof Nastran bulk Nastran op2 Patran neutral Pro Mechanica

B B A A A B A A A A B B B A B A A

Linux, Itanium2

Binary/Ascii

Linux, i686

IRIX 6.5.22, MIPS

* * * * * * * * * * * * * * * * *

Platform planning for FEMFAT 4.7 and 4.8 FEMFAT has been supporting a large number of hardware platforms for many years. This flexibility is highly valued by customers. On the other hand, every additional platform ties up development capacity that cannot be invested in the product itself. Looking at machine performance, their extent of use amongst FEMFAT users and the strategy of hardware manufacturers, then an end is foreseeable for the SUN Sparc-based systems and the MIPS-based SGI hardware. The 32 bit versions of the Linux and Windows PC operating systems are also likely to be rapidly superseded by their 64-bit successors in the technical sector. Given the widespread use of 32-bit systems, however, no definitive date has been set for discontinuing their support. The following platforms will be fully supported for a limited period: SUN Sparc versions including 4.6x (until approx. end of 2006) SGI MIPS versions including 4.7x (until approx. end of 2007) This information relates to the FEMFAT application. SUN Sparc and SGI MIPS will be suppor ted as license ser vers for as long as customers are using these systems.

Key: supports files > 2 Gb ! supports odb files > 2 Gb, although an internal transfer file must remain < 2Gb limited to 2 Gb * spring 2006 (files > 2 Gb)
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Winter Edition 2005/2006

FEMFATNEWSLETTER
User defined method In this method, the temperature dependent material data specified by the user is taken into account; this data can be defined in the menu Material data -> Properties at higher temperatures. The temperature dependent fully reversed endurance limit and the ultimate tensile strength must be defined as a minimum for this method. FEMFAT 4.6 method (default) This option is based on method 4.5, but in addition the cyclic coefficient of hardening K of the cyclic stress-strain cur ve is reduced in a similar way as the ultimate tensile strength. This means that the isothermal temperature influence is also correctly taken into account in the mean stress redistribution of linear elastic stresses according to Neuber (FEMFAT PLAST module). Isothermal temperature influence on Rm, Re and K
1,2000 1,0000 0,8000 0,6000 0,4000 0,2000 0,0000

FAQs
When/Why BASIC, ChannelMAX or TransMAX?
BASIC Uses a simple load histor y that can be described by two states and a constant component (e.g. assembly). Advantage: the analysis speed is ver y fast because BASIC holds the data in RAM. Examples: Conrod, cylinder head, gearbox casing, shafts etc. Input data required: Upper/lower stress or amplitude/mean stress Constant stress (optional) Load spectrum for damage analysis

ChannelMAX The load histor y is as complex as you wish and can be described by superimposing unit load cases (static states or modal shapes). The system response (except local plastic deformations) must be linear; up to millions of time points possible. Examples: wheel mounts, axle frames, body work, crank shafts Input data required: One stress result per channel (load direction, modal shape) One load-time sequence per channel

Influence factor

20

50

100

150

200

Temperature [C]

250

300

350

400

450

500

Steel/nickel alloy / tool steel Fine-grained steel Gray cast iron Compacted graphite iron / nodular graphite cast iron / sintered steel Malleable cast iron Cast steel Aluminum

TransMAX Most general form of the load histor y. The system response can be completely non-linear; number of time points limited to hundreds (thousands). Examples: cylinder block and other components with complex contacts. Input data required: Sequence of computed stress states over time

One can see from the curves that all temperature influences based on FKM produce conservative results.

FEMFAT startup options

The star t lines for UNIX/Linux read: femfat4 <-Option> and for Windows: CALL femfat.tcl <-Option> -ini The -ini option opens a menu immediately after startup for defining the memory allocation, interface formats and user interface. -lic This option can be used from FEMFAT 4.6 version onwards. It displays a dialog box in which one can select from the available licenses, the modules required for the current job. This is useful for all customers who have a different number of licenses for different modules. -dsp = Display# This option can be used to specify a redirection to any Ethernet address of another machine. Without a valid display, FEMFAT cannot star tup i.e. this option is often required with ser ver machines. -job = Jobname.ffj Execution of multiple FEMFAT analyses in batch mode can be automated. Similar jobs containing only slight changes e.g. filenames of FEM data - are easy to set up from an existing job.ffj file using an editor. The modified jobs are given a new name (e.g. job2.ffj, job3.ffj,..) and can be listed sequentially under UNIX/Linux in a shell script. Under Windows, the *.bat extension must be selected so that the file can subsequently be executed. A detailed explanation is given in the Introduction chapter in the FEMFAT user manual.
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Isothermal temperature influence

Enabling the isothermal temperature influence means that the local operating temperature is taken into account at all analyzed nodes (usually upper temperature). FEMFAT provides various analysis methods for this: FKM guideline method The isothermal temperature only affects the dynamic strength values in the Haigh diagram (vertical scaling). FEMFAT 4.5 method This option changes both the dynamic strength parameters in the Haigh diagram (similar to the FKM guideline) and the static strength parameters (horizontal scaling of the Haigh diagram). The same formulae from the FKM guideline are used for modifying the yield stress and ultimate tensile stress. The user is warned if the temperature exceeds the range defined in the FKM guideline, and the influence factor is extrapolated on the basis of the implemented formulae.

FEMFATNEWSLETTER
Engineering Center Steyr, St. Valentin
Fatigue life/Damage and safety factors for simple loads, comprehensive FE-interfaces and material database

Winter Edition 2005/2006

FEMFAT training courses - new dates 2006

Engineering Center Troy, Detroit
17 Februar y 2006 16 June 2006 20 October 2006 Prices (excl. VAT): per delegate Euro 770.00 23 - 24 Februar y 2006 26 - 27 April 2006 13 - 14 September 2006 6 - 7 December 2006

per additional delegate from the same company Euro 610.00

3D-postprocessor

University/research organization Euro 300.00

Including 2 month FEMFAT evaluation license

Multiaxial fatigue

Information: a.schmidthaler@ecs.steyr.com

*** NEWS *** NEWS *** NEWS *** NEWS *** NEWS *** NEWS *** NEWS *** NEWS ***
Welded structures

FEMFAT 4.6 released Good things come to those who wait! And thats cer tainly true of the new FEMFAT 4.6 version, which FEMFAT users will find under their metaphorical Christmas tree in December 2005.

As recompense for the wait - admittedly tempered by a number of interim versions - the new version includes an awesome VISUALIZER, major new inter faces and per fected features in the MAX, SPOT and WELD module. Have fun FEMFATing!

*** STOP PRESS *** STOP PRESS *** STOP PRESS *** STOP PRESS *** STOP PRESS ***
Spot-joined structures

FEMFAT Road Show, Frankfurt

Seventeen interested parties - mainly newcomers - came to a free information day at the Hotel Plaza in Frankfur t Offenbach on 8 November 2005. Using practical examples, we demonstrated potential FEMFAT applications and provided information on inter faces and all the major FEMFAT modules. Its success has prompted us to hold fur ther road shows: on 07.02.06 in Hamburg and on 11.04.06 in Stockholm. You can already register your interest with us by e-mail or phone; you will receive a separate invitation shortly.

Call for Papers and Notification

We are currently intent on informing global customers of the new range of potential applications for FEMFAT and its additional features. After a successful first Korean FEMFAT User Meeting in October 2005, we are holding the 2nd FEMFAT User Meeting Japan in the Palace Hotel Tokyo on 10 March 2006, and the 2nd FEMFAT User Meeting USA in Troy, Michigan in fall 2006. More details will appear in the next issue of the FEMFAT Newsletter. We would be delighted to reser ve a slot for any FEMFAT users already interested in presenting a paper.

PLAST

Local plasticity Static safety factors Thermomechanical fatigue Measured strain based fatigue analyses

BREAK HEAT

STRAIN

Event calendar 2006

Engine dynamics/Acoustics simulation

7th Graz Four-wheel Congress Computable Casting in the Motor Industry FEMFAT User Meeting Japan Leoben Operational Strength Conference Reliability of Mechatronic/Adaptronic Systems FEM Design Optimization Conference SAE World Congress 27th International Viennese Motor Symposium DVM Day 2006 Material Parameters 2nd Graz Commercial Vehicle Workshop

Graz Aachen Tokyo Planneralm Darmstadt Stuttgart Detroit Vienna Berlin Graz Atlanta Friedrichshafen Aachen Steyr Yokohama Detroit

02 - 03 Feb. 2006 14 - 15 Feb. 2006 10 March 2006 08 - 10 March 2006 15 - 16 March 2006 21 - 22 March 2006 03 - 06 April 2006 27 - 28 April 2006 09 - 11 May 2006 12 May 2006 14 - 19 May 2006 27 - 28 June 2006 09 -11 Oct. 2006 11 - 12 Oct. 2006 22 - 27 Oct. 2006 Fall 2006

Sub-modeling

Analysis & preparation of data

Publishers information:

Fatigue 2006 Gears in vehicles 2006 (VDI) Aachen Colloquium DVM 32nd Operational Strength Conference

Engineering Center Steyr GmbH & Co KG Steyrer Strasse 32, A-4300 St. Valentin Tel: ++43 7435 501 303, Fax: ++43 7435 501 300 a.schmidthaler@ecs.steyr.com www.femfat.com

Fisita 2006 FEMFAT User Meeting USA