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fe-safe Main Technologies

fe-safe is the most comprehensive fatigue analysis software suite on the market, enabling users to predict accurate fatigue lives across a broad range of applications, regardless of the complexity of your analysis.

Note: this is not a complete list of features in fe-safe

  • Automatic hot-spot formation - fe-safe automatically forms fatigue hot-spots based on user-defined or default criteria. Hot-spots can be used for rapid design change studies and design sensitivity analysis.
  • Critical distance - will cracks propagate? - Critical distance methods use subsurface stresses from the FEA to allow for the effects of stress gradient. The data is read from the FE model by fe-safe, and the methods can be applied to single nodes, fatigue hot-spots or any other chosen areas including the whole model.
  • Damage per block - Complex loading histories can be created from multiple blocks of measured or simulated load-time histories, dynamic response analyses, block loading programmes and design load spectra. Repeat counts for each block can be specified. fe-safe also exports the fatigue damage for each ‘block' of loading (for example, from each road surface on a vehicle proving ground, or for each wind state on a wind turbine). This shows clearly which parts of the duty cycle are contributing the most fatigue damage. Re-design can focus on this duty cycle, and accelerated fatigue test programmes can be generated and validated.
  • Distributed processing - Distributed processing over a network or cluster is available, offering linear scalability Mixed networks of Windows, Linux and Unix applications are supported. Fail-safe methods if nodes go offline and auto balancing are included.
  • fe-safe Custom Fatigue Algorithm (CFA) - fe-safe CFA allows users to create and modify fatigue analysis methods. Confidential algorithms can be created and modified (in Python, FORTRAN, C++ and other languages). fe-safe uses its own powerful fatigue loading capabilities to assemble the tensor time history, and this is passed to the Custom Fatigue Algorithm (CMA). Stress, strain and temperature variation and node-by-node material property variations are supported. User-defined results and other information are returned to fe-safe. New user-defined materials properties can be added to the materials data base. An initialisation call can generate a user interface to read text from the screen or batch file. Batch and distributed processing are also supported. By using the CMF your own algorithms can be added to those supplied with fe-safe to operate seamlessly in the fe-safe environment.
  • fe-safe/Rotate - fe-safe/Rotate speeds up the FEA and fatigue analysis of rotating components by taking advantage of their axial symmetry. The module is used to provide a definition of the loading of a rotating component, through one full revolution, from a single static Finite Element analysis. From a single load step, fe-safe/Rotate produces a sequence of additional stress results as if the model had been rotated through a sequence of different orientations (or the load had been rotated around the model).
    • Reduces fatigue analysis time
    • Reduces FEA analysis time
    • Creates smaller FEA results files
  • Manufacturing effects - Results from an elastic-plastic FEA of a forming or assembly process or from surface treatments such as cold rolling or shot peening can be read into fe-safe and the effects included in the fatigue analysis. Estimated residual stresses can also be defined for areas of a model for a rapid ‘sensitivity' analysis.
  • Materials database - A material database is supplied with fe-safe. Users can add their own material data and create new databases. Material data can be plotted and tabulated. Effects of temperature, strain rate etc can be seen graphically.
  • Parallel processing - Parallel processing functionality is included as standard - no extra licenses are required.
  • Property mapping - Results from casting or forging simulations can be used to vary the fatigue properties at each FE node. Each node will then be analysed with different materials data. Temperature variations in service, multiaxial stress states and other effects such as residual stresses can also be included.
  • Signal processing - Signal processing, load history manipulation, fatigue from strain gauges, and generation of accelerated testing signals are among the many features included as standard.
  • Structural optimisation - fe-safe can be run inside an optimisation loop with optimisation codes to allow designs to be optimised for fatigue performance. fe-safe interfaces to Isight from SIMULIA, ANSYS Workbench, TOSCA from FE-Design and Optistruct from Altair.
  • Surface contact - Surface contact is automatically detected. Special algorithms analyse the effects of contact stresses. This capability has been used for bearing design and for the analysis of railway wheel/rail contact.
  • Surface detection - fe-safe automatically detects the surfaces of components. The user can select to analyse only the surface, or the whole model. Subsurface crack initiation can be detected and the effects of surface treatments allowed for.
  • Test programme validation - fe-safe allows the user to create accelerated test fatigue programmes. These can be validated in fe-safe to ensure that the fatigue-critical areas are the same as those obtained from the full service loading. Fatigue lives and fatigue damage distributions can also be correlated.
  • Vector plots - Vector plots show the direction of the critical plane at each node in a hotspot, or for the whole model. The length and colour of each vector indicates the fatigue damage.
  • Virtual strain gauges - Virtual strain gauges (single gauges and rosettes) can be specified in fe-safe to correlate with measured data. fe-safe exports the calculated time history of strains for the applied loading. FE models can be validated by comparison with measured data.
  • Vibration Fatigue - fe-safe includes powerful features for the analysis of flexible components and structures that have dynamic responses to applied loading. Steady state modal analysis, random transient analysis and PSDs are among the analysis methods included. fe-safe includes a revolutionary new method for fatigue analysis of PSDs of loads, combining a unique method of superimposing multiaxial PSDs with critical plane analysis.
  • Warranty curve - fe-safe combines variations in material fatigue strengths and variability in loading to calculate the probability of survival over a range of service lives.
  • Welded Fatigue - fe-safe includes the BS708 analysis as standard. Other S-N curves can be added. fe-safe also has an exclusive license to the Verity Structural Stress Method developed by Battelle. Developed under a Joint Industry Panel and validated against more than 3500 fatigue tests, Verity is bringing new levels of accuracy to the analysis of structural welds, seam welds and spot welds.