Durability Analysis Software for Finite Element Models.

What’s new in fe-safe 2016

Naming convention and Release cycle synchronization
All versions of Portfolio Products will now follow the year-based naming convention to be consistent with each other and consistent with the other SIMULIA product releases that will be occurring at that time.

  • Abaqus 6.14 -> Abaqus 2016
  • Isight 5.9 -> Isight 2016
  • fe-safe 6.5 -> fe-safe 2016
  • Tosca Structure 8.1 -> Tosca Structure 2016


Enhancement Summary

  • Improved fatique analysis algorithm to comply with FKM Guidelines
  • Improved ANSYS Workbench extension
  • Automated weld analysis expanded to shell element models
  • Enhanced project management
  • Licensing changes
  • Verity - improved through-node handling
  • Improved surface element analyses in Pro-Mechanica
  • Collapsed element handling
  • Material search client integration
  • New Manson-McKnight Octahedral fatigue algorithm

FKM Guideline Algorithm

This new algorithm option provides fatigue analysis from finite elements in accordance with the FKM Guideline ‘Analytical Strength Assessment of Components, 6th Edition’. Compliance is assessed by the degree of utilization, based on the ratio of the largest stress amplitude to the variable amplitude fatigue strength.  Assessment of the component fatigue strength is achieved if the maximum degree of utilization is not greater than unity.
There are two new material databases with fe-safe 2016 to be used with this new algorithm, compiled from the tables of materials in the FKM Guideline. These include around 300 steels and cast iron materials, and around 1000 aluminum materials. In addition, the existing material databases have been modified to allow other materials to be used with this algorithm.

Redesigned ANSYS Workbench Extension

fe-safe 2016 now comes with an entirely new extension component for ANSYS Workbench 15 and 16. The highlights of the new development are:

  • fe-safe results contours can now be viewed directly within ANSYS Mechanical with no awkward post-processing
  • fe-safe analysis groups can be based on named selections, bodies or faces
  • Verity workflows are now supported
  • Basic loadings and surface finish information can be specified without leaving the ANSYS Mechanical application
  • Units are read automatically from Workbench
  • Support for the previous Workbench extension has been discontinued for fe-safe 2016.


Automated weld analysis expanded to shell element models

The automatic detection of weld failure modes for use with Verity now allows welds modeled with shell elements. A single group with all shell and solid weld fillet elements can be defined and fe-safe will detect the weld lines and failure domains required to correctly analyze the welds. In addition, for shell welds, the root failure mode can automatically be detected.

Enhanced Project Management

Within fe-safe 2016 projects can now be easily managed and controlled. In addition to basic functionality like creating a new project or loading an existing one, projects can be exported to and imported from a single compressed file. With the ability to select specific categories of files for export this feature can easily and quickly be tailored for many situations, from archiving all or just the results files, excluding external project files and any results for submission later or on a remote machine or cluster, to stripped out FED data (or source FE model) for use in an optimization environment.

To give additional support for later batch submission a helper macro can be written out with an exported project. There are also extensive macro commands for all project management as well as command line options for extracting a project as fe-safe starts. It is now also possible to switch between projects without having to close the fe-safe session.

Licensing Changes

Both SIMULIA FlexNet and DSLS now fully support redundant servers when specifying license servers.

Extended token use in fe-safe has been changed to allow users even more effective use of their licenses by no longer requiring a client QFX/QAX licence for job, batch, verity and output functions when submitting them on the command line.


Verity - improved through-node handling

On curved weld sections the weld line normal is often not aligned with the meshed element edges, which causes problems in locating associated through-nodes, especially in tetrahedral meshes. The Solid Weld finder code was enhanced to provide more robust ray tracing through the mesh to find edges (or points close to edges) where the weld-line normal leaves an element.
Virtual through nodes are provided by interpolation (unlike the original Verity "station points" which have to be equally-spaced). Also where a wide cone tolerance is used the located through node list is pruned as it often “double counts” nodes from neighbouring line nodes. Where there is a cluster of through nodes at similar projected distance from the line, only the best-aligned one is retained.

Improved surface element analyses in Pro-Mechanica

Pro-E analyses of only surface elements using fine-scale H-nodes could not be performed (except by potentially less accurate P-node interpolation). This has now been fixed by reading in the H-element mesh as well as the P-element mesh.


Collapsed element handling

More robust handling of collapsed elements is provided, typically affecting Verity, PSD, and TCD analyses using ANSYS models. Previous versions could have given node failures in TCD or PSD Shear algorithms due to failures in surface normal calculations on faces involving collapsed elements, or potentially incorrectly aligned normal at model edges or corners with one face collapsed. Verity with welds defined using the new weld finder can include collapsed elements along the weld line.

Material search client integration

Two changes have been made to the external material database that accompanies fe-safe.

Firstly, it is no longer necessary to launch the database server explicitly. On Windows, the start menu link ‘External Material Database’ under fe-safe 2016 will invoke both the material search client and an instance of the server.

On Linux, both client and server can now be launched simultaneously using a new executable called material_launcher in the installation directory.

Secondly, the material database client and server can be launched from within fe-safe by clicking a new button in fe-safe’s Material Databases window.

New Manson-McKnight Octahedral fatigue algorithm

This compliance algorithm may be required by national regulatory bodies e.g. in the aviation sector.  It is a multiaxial fatigue model which allows for a multiaxial stress state and mean-stress effects to be accounted for.  It is based on the concept of a signed von Mises mean stress and is a partial implementation of the fatigue algorithm used in NASA’s NASALIFE fatigue-prediction software.
This replaces the Modified Manson-McKnight NASALife and Fillipini algorithms in previous versions of fe-safe.  Unlike those algorithms, it performs cycle counting and is therefore suitable for complex load histories.


Other Enhancements

  • ANSYS v16 RST files are now supported
  • Abaqus 2016 ODBs are now supported
  • Add support for many more loading blocks than 4097
  • Added support for the SRF export file format for SIMPACK
  • Extended material database has been updated with new materials
  • ASME Verity plugin is now included on the fe-safe distribution
  • Added the Abaqus License Server binaries to the fe-safe distribution
  • Drag and drop can now be used to append FEA solutions
  • Extend the material's default algorithm selection to include plug-in algorithms
  • Improved clarity of Material and Group settings in Isight
  • Changed default installation directory in line with Simulia product line
  • Enable use of EN table data in TURBOlife
  • Plugins can now request non-standard variables in ANSYS RST reader
  • Academic and teaching licenses are now supported
  • The General FEA Options dialog has been re-organized for clarity
  • The Algorithm picker dialog has been redesigned