Fatigue User’s Guide > Fatigue Utilities > Advanced Fatigue Utilities
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Advanced Fatigue Utilities
Ten advanced modules are available as single location fatigue analyzers and/or for display of fatigue damage and cycles information. It is assumed that the user has a good working knowledge of MSC.Fatigue’s analysis capabilities before attempting to use these modules. Please familiarize yourself with Using MSC Fatigue (Ch. 2) and Total Life and Crack Initiation (Ch. 5) first, if this is not the case.
Single Location S-N Analysis - (MSLF)
The MSLF program models fatigue life to predict durability based on SN-curves derived from constant amplitude test results for specimens or components. In this way, failure can be predicted in a total life sense for any component subject to any variable amplitude or service measured time history using the Miner Rule of linear damage calculation. In MSLF, a single fatigue life answer is not the end point, only the beginning of potentially very many “what if” and sensitivity studies using multiple input parameters and back calculations with varying scale factor, mean stress offset, % certainty of survival, stress concentration factor, size effect, surface finish and surface treatment.
The reader is referred to Total Life (S-N) Analysis, 1318 for theoretical information on stress-life (S-N) fatigue analysis. This section highlights the functions of the MSLF module.
MSLF is very similar to MCLF and it is assumed that the user has a working knowledge of the MSC.Fatigue module FEFAT. The difference between MSLF and MCLF is that MSLF requires stress response information and MCLF requires strain responses. The difference between MSLF and FEFAT is that MSLF begins with a stress response (in the form of a .dac file and could be from measurement data) and is a single location analyzer, whereas FEFAT requires load input and stress from FE models. They work together well when a response stress signal is output from FEFAT from a single location of the FE and feed into MSLF.
MSLF can be used when considering the fatigue performance of:
Welds and other structures which may contain cracks or crack- like defects.
Machined components
Forgings
Castings
Pressings
Non-metals; e.g. plastics, composites etc.
MSLF, like the other fatigue analyzers in the MSC.Fatigue system, can be used for:
Durability assessments in the design/test loop to avoid costly and time consuming prototype repeat testing
Durability Optimization by “what if studies” to achieve better fatigue solutions (loading, material, surface condition, local geometry)
Failure analysis by mimicking the failure and providing substantiated remedial solutions
Optimization of inspection and maintenance scheduling by fatigue assessments and updates
Computer simulation prior to structural testing to optimize test programs from a fatigue content perspective and to optimize time, budget and testing resources
Optimization of materials selection and manufacturing process routes (casting, forging, machining, shot peening) from a fatigue durability viewpoint.
Kt values can be determined within Time Correlated Damage - (MTCD), 1072 and passed into MSLF as default selections. MSLF also supports the calculation of Kf values from Kt. A full range of postprocessing and results display options are available in MSLF. Other features of MSLF are similar to the other fatigue analyzers in the MSC.Fatigue system and only those items unique to MSLF are expounded on here.
Module Operation
The MSLF module can be run in one of the following three modes:
From the Advanced Fatigue Utilities pulldown menu under Tools | MSC.Fatigue (for Patran) or under Tools | Fatigue Utilities (for Pre & Post).
In stand alone mode by typing mslf at the system prompt.
By incorporating the MSLF commands in a batch operation.
Once running in interactive mode, the MSLF module will display the following screen:
Figure 13‑32 The First MSLF Screen
The user must enter the name of an Input Job File, which have .fjb extensions. If the name of an existing Job File is entered then MSLF will go to the postprocessing. If a new job is specified then its parameters have to be entered in a series of screens. If no name is entered then the results of processing may NOT be saved.
The flow chart below illustrates the major routes through MSLF.
Figure 13‑33 The General Module Structure (MSLF)
 
The Loading Environment
This input for MSLF is identical to that of MCLF with the exception of a few items that MSLF does not need. See Service Loading Environment, 1046.
Three types of loading file can be specified:
Time History which normally means a single parameter .dac time history or .pvx peak valley file. This can be a measured time history or a time history extracted from FEFAT.
Range Mean Matrix which normally means a rainflow matrix file with a .cyh extension.
Constant Amplitude which requires the user to enter individual values of Amplitude and Mean Value.
For all file types the data should preferably be in units of Microstrain (uE). If they are NOT then a calibration file that contains the appropriate conversion factors should be supplied.
Model Parameters
All input on this page is identical to that required for a global FE fatigue analysis. See Model Parameters, 1051.
Nominal S-N curves can be either structure, component, or specimen based. One of the three analysis methods must be chosen. Briefly they are:
Material S-N which are S-N curves generated from the elastic part of the strain controlled fatigue tests or S-N curves for which Kt = 1.0
Component S-N which are generated directly from stress based fatigue tests on components and the associated Kt > 1.0.
BS7608 which are S-N curves designed to be used as part of BS7608 part 10 analysis of welded structures.
It is important to maintain consistency between the analysis methods selected here and the S-N datasets chosen in the next screen.
Material Data Input
All input on this page is identical to that required for a global FE fatigue analysis. See Material Data Input, 1051.
Note that using Material Management (Ch. 3), can approximate S-N damage curves and can be generated purely on the basis of ultimate tensile strength (UTS). The curves are constructed by fixing the stress axis intercept, 1 cycle, at the value of the UTS, fixing the stresses at 1000 cycles and the endurance limit according to the fractions of UTS detailed below:
 
Alloy Type
Cycles
Stress
Ferrous Alloys
1
1.000 x UTS
 
1,000
0.900 x UTS
 
1,000,000
0.357 x UTS
Titanium Alloys
1
1.000 x UTS
 
1,000
0.800 x UTS
 
1,000,000
0.307 x UTS
Aluminum Alloys
1
1.000 x UTS
 
1,000
0.700 x UTS
 
500,000,000
0.258 x UTS
Other Alloys
1
1.000 x UTS
 
1,000
0.800 x UTS
 
100,000,000
0.274 x UTS
Geometry Screen
All input on this page is identical to that required for a MCLF. See Geometry Screen, 1052.
A brief discussion of Notch Correction Factors Kf from Kt:
If Kf is not known then it can be calculated from a user supplied Kt value. MSLF that takes material properties, notch radius, and notch depth into account, and uses hard coded lookup tables, to calculate Kf.
The user-defined Kf value is used to modify the S-N curve at the transition life’NC1’ by dividing the stress by Kf. The S-N curve is also modified at N=1E3 by dividing by Kf’, which is determined from a hard coded Figure 13‑34 below, which is taken from R C Juvenall’s paper, ’Engineering Considerations of Stress, Strain, and Strength’ McGraw Hill, 1967.
Figure 13‑34 Relationship Between K’f and Kf as a Function of Ultimate Strength
The above figure illustrates the relationship between (Kf’)/(Kf-1) and the UTS of the material at N=1E3. If the user defines a Kt value and the software calculates Kf, the software makes exactly the same adjustment at the transition life. At 1E3 all corrections made to the S-N curve are based on the fatigue notch factor Kf. The second slope is not changed at all - only the intercept is changed to make the transition life the same.
Results Setup Screen
This setup is also virtually identical to that of MCLF. See Output Setup Screen, 1053.
MSLF can generate a number of different output files depending on the analysis path chosen. If a multiple analysis has been specified in any of the input screens, then a single file, with the results name provided, with any one of the following file extensions, depending on the multiple parameter, will be created.
 
.fal
Scale factor vs. Life
.gal
Hysteresis gate vs. Life
.ofl
Offset vs. Life
.kfl
Kf vs. Life
.ktl
Kt vs. Life
.dcl
Survival probability vs. Life
All these files have the standard MSC.Fatigue X-Y paired data format and can be displayed graphically within MSLF itself or by the X-Y parameter display module, MTPD. No other output files will be created.
If, on the other hand, a single shot analysis has been carried out then MSLF can optionally create a group of files which contain different information, have the same results name and the following file extensions.
 
.cyo
Rainflow matrix suitable for input to MCDA or MP3D
.dhh
Damage matrix suitable for input to MCDA or MP3D
.slf
List of fatigue cycles and associated damage suitable for input to MCDA.
All these files may be displayed graphically from with MSLF.
Like MCLF these files, numerical results are also written to the extra details area of the damage matrix file, .dhh extension. See Environment Keywords, 1057.
The Postprocessing Menu
See the The Postprocessing Menu, 1056 postprocessing menu. Operations are identical.
Batch Operation
It is recommended that, by default, the /OV=Y keyword be included in every batch command line, since if it is omitted and an output file with the specified name already exists, batch operation will cease.
When batch processing with a series of different input files, it is necessary to use a new batch line and option definition for each new input. The new line must specify the option from the postprocessing menu into which the new input will go. For example, when using the jobfile fatjob.fjb:
mslf /job=fatjob.fjb/inp=datafil1.dac/opt=l
			mslf /job=fatjob.fjb/inp=datafil2.dac/opt=l/opt=g/kf=2.0
			mslf /job=fatjob.fjb/inp=datafil3.dac/opt=l/kf=2.5/opt=g
Which will run MSLF three times with a different strain history file each time. Omitting the /OPT keywords will cause the batch file to fail because inputs without the /OPT=L keyword the .dac files cannot be loaded and will therefore be ignored (the values in fatjob.fjb will be used instead). Each run of MSLF with a new input for the fatigue job needs a new batch line.
Note that it is permissible to input more than one parameter on a batch line, but they must be different. Note also that the order in which the batch keywords appear is not critical. Also all notes associated with MCLF batch operation also apply to MSLF operation. Batch keyword for MSLF:
 
/OPTion
Back page option, e.g. /OPT=M, to input a new Model parameter. Also L,S,G,O,D,J,P,C,R,X
/INPut
The name of the input data file. /INP=INDATA
Needs /OPT=L if a new file is to be loaded into a job already created.
/FACT
The required scaling factor(s). /FACT=2.5
/DCrit
The %certainty of survival. /DC=50
/ANAL
The required analytical procedure, M, C, or B.
/MSC
Mean stress correction method, N=None, G=Goodman, B=gerBer, All
/ANAL
The analysis method: Material s-n, Component s-n, or Bs5400. /ANAL=B
/UTS
The Ultimate Tensile Strength of the material. /UTS=675
/GATE
The required hysteresis gate. /GATE=500
/LIFe
/LIF=10000
If BACK has been specified for this keyword then /FA= specifies the required life.
/SNC
The name of the material data set to use. /SNC=SNDATA
/EDIT
Specifier to edit a material parameter prior to analysis. /EDIT=SRI=10075.
This keyword can be used any number of times.
/OUT
The name of the output results file. //OUT=RESULT
/OVer
Whether to overwrite an existing results file. /OV=Y
/PLT
Request a hardcopy plot of factors or design criterion vs. life plot. /PLT
/PLTNAM
The name to assign to the required plot file. /PLTNAM=MYPLOT
/TYPE
Loading type is; T=Time, R=Range-mean, or C=Constant temp. /TYPE=R
/CALFIL
Calibration file; N=No, ASCII, or B=Binary. /CALFIL=B
/UNIT
MPa, KSI, uE. /UNIT=MPA
/AMP
Amplitude(s). /AMP=
/MEAN
Mean(s). /MEAN=
/STA
Start time. /STA=10
/END
End time. /END=100
/CALNAM
Calibration file name. /CALNAM=test
/LUNI
Loading units from cal file. /LUNI=MPA
/OFF
Offset. /OFF
/NUMEQU
Number of equivalent units. /NUMEQU=34
/EQUNIT
Equivalent units string. /EQUNIT=
/DESign
The design criteria. /DES=
/MINERs
Miner's value. /MINER=1.5
/JOB
Jobname. /JOB=Newjob
/CREate
Create new job Y/N. /CRE=Y
/MATENTry
Material entry method. /MATENT=
/SNDATa
S-N data set name. /SNDAT=Fred
/SURFace
Surface finish, PO,GR,GO,POO,AM,HO,F,C,WC,SC,UD. /SURF=GR
/TREATments
Surface treatments, NONE,NITRIDED, COLD ROLLED, HOT PEENED, AL. /TREAT=Nitrided
/CLASS
Weld class. /CLASS
/WELDED
Welded yes/no. /WELDED=Y
/THICKness
The thickness of the weld. /THICK=20
/WCORRosion
Correct for corrosion Yes or No. /WCORR=Y
/YModulous
Young,s modulus. /YM=3E3
/N1
The first S-N entry point. /N1=
/S1
The stress amplitude at S1. /S1=
/N2
2nd S-N entry point. /N2=
/S2
Stress amplitude at S2. /S2=
/SLOPE
Slope after N2. /SLOPE=
/SERR
Standard error at log(x). /SERR=
/RATIO
R-ratio at test. /RATIO=
/GENTYP
Type of material generated. /GENTYP=
/SRI1
Intercept on Y-axis of S-N plot for edit option (see fig 7). /SRI1=
/B1
First slope for, edit option. /B1=
/NC1
Transition life, edit option. /NC1=
/B2
Second slope, edit option. /B2=
/KT
Kt value(s). /KT=
/ADDKF
Additional Kf values. /ADDKF=
/HTYPE
Histogram type, None, Input units. /HTYPE=
/CYC
Cycles file, Y/N. /CYC=
/SIZE
Histogram size. /SIZE=
/LIMits
Limits are User or Auto. /LIM=
/DAMUNI
Damage units A, P, N. /DAMUNI=
/XYFIL
Create and X-Y file of multiple results Y=yes or N=no. /XYFIL=
/DAMage
Damage histogram file Y/N. /DAM=
/RMIN
Histogram file limit. /RMIN=
/RMAX
Histogram file limit. /RMAX=
/MMIN
Histogram file limit. /MMIN=
/MMAX
Histogram file limit. /MMAX=
/PRFOPT
Preference option, M,B,U. /PRFOPT=
/UNIOPT
Material units setting, MP,P,K,N,MN. /UNIOPT=
/TOLERance
Back life tolerance. /TOLER=
/MATCHK
Material checking. /MATCHK=
/NEWJOB
Job name to save as. /NEWJOB=
/JOBOPT
Start another job or 'save as' (see NEWJOB)
/AUTOVer
Auto overwrite preference Yes/No. /AUTOV=
Single Location ε-N Analysis - (MCLF)
Local (single location) stress-strain fatigue analysis is used to estimate the number of cycles required to initiate an engineering crack. Similitude between the material at a critical location, such as a notch, and the material in a smooth specimen, subjected to similar loading conditions, is assumed. MCLF uses this methodology to predict the presence of engineering cracks of about 2 mm length.
Each calculation session is associated with a fatigue job file which contains details of all the parameters required for an analysis; in this way a set of default fatigue environments can be defined. For complex jobs, the fatigue job file is particularly useful since it obviates the need to re-enter parameters from one session to the next unnecessarily. Multiple and “back” calculations are performed quickly and easily and provide convenient X-Y type plots of life variation.
Analysis proceeds by tracking local stress and strain, identifying fatigue cycles by means of rainflow cycle counting, correcting for the effects of geometry, surface finish and treatment and estimating partial damage. Finally, total damage is calculated by linear damage summation.
Module Operation
The MCLF module can be run in one of the following three modes:
From the Advanced Fatigue Utilities pulldown menu under Tools | MSC.Fatigue (for Patran) or under Tools | Fatigue Utilities (for Pre & Post).
In stand alone mode by typing mclf at the system prompt
By incorporating the MCLF commands in a batch operation
The first two modes are interactive. Once running in interactive mode the MCLF module will display the following screen.
Figure 13‑35 The First MCLF Screen
The user must enter the name of an Input Job File, the extension .fbj will be appended automatically. If the name of an existing Job File is entered then MCLF will go to the postprocessing menu screen straight away. If a new job is specified then its parameters have to be entered in a series of windows. A name is not required to continue but the results of processing may not be saved.
The flow chart below illustrates the major routes through MCLF.
Figure 13‑36 The General Module Structure (MCLF)
The MCLF module works in much the same manner as FEFAT. It is assumed that the user has a good understanding of the FEFAT module.
MCLF is essentially an extension of FEFAT to allow more precise fatigue calculations from a strain time history, either measured or calculated from FEA. MCLF is used in conjunction with FEFAT by extracting a strain time history for a particular location to feed into MCLF. Because much of the operation of MCLF is identical to FEFAT, only those features unique to MCLF are explained here. See FE Fatigue Analysis Options (FEFAT), 276 for details of the other options.
The following input is necessary to define a fatigue job:
Service Loading Environment
Option
Description
Loading
One of the main inputs for a fatigue life estimation is the file that describes the loading environment to which the component or assembly is to be subject. Three types of loading file can be specified:
Time History which normally means a single parameter .dac time history or .pvx peak valley file. This can be a measured strain time history or a strain time history extracted from FEFAT.
Range Mean Matrix which normally means a rainflow matrix file with a .cyh extension.
Constant Amplitude which requires the user to enter individual values of Amplitude and Mean Value.
For all file types the data should preferably be in units of Microstrain (uE). If they are NOT then a calibration file that contains the appropriate conversion factors should be supplied.
Calibration File
Any other system of units such as those associated with load or force etc., can also be used provided that the appropriate conversion function is supplied by means of a calibration file.
Calibration files have a ASCII format. A calibration file must have the following structure: Input on X and output on Y, where output must be in the default internal units,i.e. microstrain, and input can be any user unit. The data pairs must be entered X (input) followed by Y (output), with one pair per line. A space is a sufficient delimiter between X and Y values.
The calibration should increase monotonically from the smallest values to the largest. If necessary MCLF will linearly extrapolate beyond the ends of the calibration. Internally, MCLF interpolates between specified values.
The units of both the input and output should be specified. In the case of an ASCII file, these units are defined through the use two comment lines (lines preceded by the # character) at the beginning of the file, e.g.
#input=Newtons 
#output=MICROSTRAIN 
-1000 -100
0 10
1000 150
In this case input in Newtons is related to output units of microstrain. As a guide note that:
Microstrain = absolute strain x 1E6
Microstrain = per cent strain x 1E4
Microstrain = per mil strain x 1E3
Strain State
Axial Loading: Typically, at the surface of a component, the stress normal to the surface is zero and conditions of plane stress are said to prevail. Under these circumstances (and if the maximum principal strain remains relatively stationary throughout the loading sequence), it is appropriate to use uniaxial properties directly.
Plane Strain Loading: If the component thickness is large relative to the notch root, and transverse contraction is effectively prevented, then plane strain conditions prevail. Typically, such conditions may be found on the surface of a thick-walled cylinder, or very thick sections. The triaxial stress state, found in plane strain, effectively alters the uniaxial cyclic stress-strain curve in the first principal direction. This modified curve is obtained by noting that the transverse strain and the stress normal to the notch surface are both zero and applying the Hencky plastic flow laws. If no entries are found in the material data base, then in the correction procedure an elastic Poisson's ratio of 0.3 and a plastic ratio of 0.5 are assumed.
Shear Strain: Conditions of pure shear arise when the biaxiality ratio approaches -1. A typical situation is of a shaft loaded in torsion. If the shear strain state is selected, MCLF will expect the input loading to be in terms of a shear strain history (usually the signed absolute maximum). Such histories are obtained through the use of strain gauge rosettes together with the appropriate outputs from the stress-strain analysis module, MSSA. The uniaxial material parameters will be automatically adjusted to account for this strain state.
Strain type
The strain input to MCLF can be in one of two forms. The first is measured strain, which was the default for this program in previous versions. This strain is assumed to lie on the cyclic stress-strain curve, whereby if yield has occurred then the strain will change in a non-linear way as load increases. The strains will be in this form if a strain gauge has been used.
Alternatively, the strain may have been calculated theoretically, from classic elastic theory or from finite element analysis. In this case the strain is usually linear elastic, and MCLF must use a different method to calculate local stress and strain.
File Name
The name of the loading file should be entered in this field. Note that if Loading = Time History then MCLF expects a single parameter .dac or .pvx file to be entered. If Loading = Range Mean Matrix then a .cyh file is expected. File names with other extensions can also be typed in this field.
Amplitude and Mean
Multiple values of amplitude OR mean can be entered. For example entering (1000,5000,500) will calculate values from 1000 to 5000 inclusive at intervals of 500. Entering 1000,2000,3000 (without the brackets) will calculate values at 1000, 2000, and 3000. MCLF will run the calculation for them all (although as only one multiple analysis criteria is allowed per run no other criteria can be multiple). “BACK” can also be entered, in which case the required life must be entered and MCLF will calculate the amplitude and mean required to achieve that life. The Show button on the right of the header bar can be used to display the values that will be processed.
Time Window
Not all of the Loading Time History file has to be used in the calculation. If only a part of the file needs to be used then the start point and end point can be specified in the Time Window. The default is to use all of the time history file, which is why the defaults are START and END.
If a part only is to be used then clear the fields and enter the values, i.e., 10 in the Start field and 1000 in the End. Alternatively the syntax START+n and END-n' where n is a number of units (e.g. seconds) from the start of the file and n' is a number of units before the end of the file. START and END are usually recorded in the header area of the input file. Please note that start is not necessarily zero.
Calibration file and units
The use of a calibration file to convert input loading units to microstrain has been specified. In this field the name of the file which contains the calibration, in the appropriate format, must be provided.
As a default, calibration files are assumed to have the file name extension .cal and so, the required file may be selected by entering its name directly without this extension.
In the units field, enter the units of the input, X, half of the calibration file. This can be any text string and is used only for reporting the units back to the user.
For Scale Factor, Offset, and Cycles Gate: if multiple entry is employed then a Damage Matrix, Rainflow Matrix, or Cycles File will NOT be produced, although MTPD will plot the results and will allow them to be stored as a hardcopy plot file.
Scale Factor
The scale factor is an amount by which the loading history or matrix will be multiplied. Multiple scale factors can be entered separated by commas or as, for example entering (-500,1000,50) in the field will scale from -500 to +1000 inclusive in steps of 50.
BACK may also be entered in which case MCLF will calculate the scale factor needed to achieve the required design life.
Offset
The offset is a value added to the results file(s) after the scale factor has been applied. For example, if the original loading file had an amplitude of 10 and a scale factor of 30 then the result (300) would then have the Offset applied. If the offset was -5 then it would be 300-5, or 295.
Cycles Gate
The gate is in effect, a filter that speeds processing by filtering any small cycles that are unwanted (for example signal noise). The gate value should not be set too high or it will filter out relevant parts of the signal. Any signal smaller than the gate value specified in this field will be ignored in the life calculation.
Multiple gate values can be entered using the same syntax as the example given for scale factors (above). No results file will be saved if a multiple analysis is carried out. A multiple gate analysis can be used to assess the gate value so that the user can choose the gate threshold that just fails to remove genuine damaging events.
The gate threshold value is sensitive to changes in material and Kf. Also if a signal is scaled up by 2, the gate is NOT automatically scaled up by 2, the user must manually scale up gate.
This Input File is Equivalent to...
The fatigue analysis to be carried out is through the use of a either a time series, range-mean matrix or a sequence of peak valleys. The results will normally be presented in the form of the number of repeats of these series to failure.
An equivalent unit, such as miles, laps, hours, etc. can be attached to the input loading file so that results can be presented in the form of miles, laps or hours to failure.
Model Parameters
All input on this page is identical to that required for a global FE fatigue analysis. See Solution Parameters, 26.
Material Data Input
All input on this page is identical to that required for a global FE fatigue analysis. See Materials Information Form, 36.
Geometry Screen
 
Option
Description
Method
The elastic stress concentration factor, Kt, is the ratio of the maximum stress at a stress raiser to the nominal stress computed by the ordinary strength- of-material formulae, using the dimensions of the net section. It can be used to account for the presence of a notch within a component or structure.
The magnitude of the Kt required depends on the nature of the notch and its geometry. Values of stress concentration factors can be obtained from standard works such as: R.E Peterson's 'Stress Concentration Factors', John Wiley & Sons, Inc. 1974. Alternatively use can be made of the Time Correlated Damage - (MTCD), 1072 module.
It is well known that small notches have less effect in fatigue than is indicated by Kt. This has led to the idea of a fatigue concentration factor, Kf, which is normally less than Kt, being introduced and being used to replace Kt within Neuber's rule.
Kf is related to Kt according to:
Kf = 1 + (Kt - 1) / {1 + }
p' is a material constant dependent on grain size and strength and r is the notch root radius.
If Kf is not known, then estimate the theoretical stress concentration factor, Kt, and select the calculate option, otherwise select the direct entry option.
Kf vs. Kt
If Kf or Kt are being entered directly other fields, such as notch root radius, do not appear.
Single or multiple values of either Kf or Kt may be entered. Alternatively, the word back, or BACK, may be entered in which case MCLF will request the entry of a desired life and then will calculate the Kf required to achieve that life.
Note that only a single arithmetic operation between delimeters (comma or space) can be undertaken, so 3+3/2 would cause an error.
Notch Root Radius (r) and Notch index (q)
Enter a value for the notch root radius in mm. A value will enable MCLF to calculate q and display it in the Notch Index q field. The notch sensitivity index, q, has been found to be a function of both material and notch radius. Neuber has defined q as:
q = 1 / {1 + √(p'/r)}
where:
p' is a material constant dependent on grain size and strength and r is the notch root radius.
The parameter p' has units of distance, mm, and for a medium strength steel with a UTS of 750 MPa has a value of about 0.1 mm.
The notch index q can only be calculated for steels that have a UTS of 50 - 250 ksi (about 340 - 1700 MPa).
Additional Kf
The fatigue strength of a component can be reduced further as a result of metallurgical defects such as inclusions or porosity. This field allows such additional Kf effects to be included in the life calculation. The number entered here will be multiplied by the value of Kf above, and the resultant combined value used in Neuber's rule. When the multiplication has been done the calculated Kf is displayed in the Calculated Kf field. When setting up a new Job the next data to be defined is the Output Definition screen (also called the Results Setup screen) which is explained below.
Output Setup Screen
MCLF can generate a number of different output files depending on the analysis path chosen. If a multiple analysis has been specified in any of the input screens, then a single file, with the results name provided with any one of the following file extensions, depending on the multiple parameter, will be created.
 
.fal
Scale factor vs. Life
.gal
Hysteresis gate vs. Life
.ofl
Offset vs. Life
.kfl
Kf vs. Life
.ktl
Kt vs. Life
.dcl
Survival probability vs. Life
All these files have the standard X-Y paired data format and can be displayed graphically within MCLF itself or by the X-Y parameter display module, MTPD, which is automatically invoked from MCLF.
If, on the other hand, a single shot analysis has been carried out then MCLF can optionally create a group of files which contain different information, have the same results name and the following file extensions.
 
.cyo
Rainflow matrix suitable for input to MCDA or MP3D
.dhh
Damage matrix suitable for input to MP3D
.clf
List of fatigue cycles and associated damage suitable for input to MCDA.
.slp
Hysteresis loops suitable for input to MTPD.
All the above files may be displayed graphically from within MCLF.
In addition, numerical results are written to the extra details area of the damage matrix file, .dhh extension. The following table details the keywords and values stored.
 
Keyword
Value
Description
ANALYSIS
CLF
Program responsible for analysis
MSC
S-W-T
Mean stress correction method
DCRIT
50.0
Probability of survival used
FACTOR
1
Scale factor
GATE
0.0
Hysteresis gate used
OFFSET
0.0
Offset used
KF
2
Fatigue strength reduction factor used
MINER
1
Miner's constant used
HISTORY
test101.dac
Load history used
MATERIAL
MANTEN
Material used
EQUUNITS
Repeats
Equivalent units
NUMEQUNI
1
Number of equivalent units
UTS
552
Ultimate tensile strength of material use
$CYCHEXT
test101.cyo
Rainflow matrix id, for system use only
MEANLF
3331
Mean life calculated
MINLF
3780
Life associated with minimum fatigue damage
MAXLF
2899
Life associated with maximum fatigue damage
The type of output requests are:
 
Option
Description
Histogram type
If none is selected here, then no histogram damage file is generated. If Input Units is selected then a damage histogram file will be generated with the same units as the input file. Selecting Nominal uE or Local uE will produce histograms scaled in strain units, either nominal elastic or local elastic-plastic ones respectively. A histogram with the axes scaled in terms of strain amplitude and maximum stress is produced by selecting the SWT option. The number of bins can also be specified.
Damage Units
The units of the damage displayed in each cell of the damage matrix can be specified. The damage can be output as actual damage values, as percent damage or damage normalized to 1.0. Select the required units.
Cycles file
In the case of a single shot fatigue life estimation, an output results file can be generated. This file contains details every cycle extracted by the rainflow algorithm, in terms of its nominal stresses and strains together with the associated fatigue damage.
The cycles file may be viewed and searched using the list cycles option on the display results menu or postprocessed using the MCYL module.
Histogram Limits
The limits of the rainflow and damage matrices can be automatically determined to match the limits of the data, or they can be 'User' specified. If they are user-specified then the range and mean minimum and maximum fields (described below) become active.
Range Minimum/ Maximum
The range limits can be manually specified in these two fields in the units specified.
Mean Minimum/ Maximum
The mean limits can be manually specified in these two fields in the units specified.
Hysteresis Loops and Number of Loops
In the case of a single shot analysis, an output file which contains the 'n' largest hysteresis loops, i.e., stress-strain cycles, extracted by the rainflow algorithm can be generated. The contents of this file may be displayed graphically by selecting the plot loops option on the display results menu or by invoking the X-Y plotting module, MTPD.
The file created will have the same generic name as given to the cycles and damage matrices but its extension will be .slp. Select Yes or No for this file.
The number of loops to be saved in the output file can be specified here. Note that the default is the 5 largest loops. Any positive number can be entered. Use the display loops option to view the loops.
The Postprocessing Menu
The postprocessing menu of MCLF is virtually identical to the Design Optimization, 290 menu of the FEFAT module. The two items that differ are the results display and listing.
This displays the results of the most recently calculated life estimation. Exactly what is available for display depends upon the calculation; if an X-Y file was not created then it cannot be displayed, a multiple calculation will not produce any histogram files, etc.
 
Option
Description
Cycle matrix 3D
Display a rainflow cycles matrix file as a 3D plot. Such a file may have been calculated or entered into the analyzer. MCLF actually loads the plot 3D module MP3D for this type of display. If a damage matrix file (.dhh) was also created during the current analysis it can also be loaded from within MP3D.
Damage matrix 3D
Display a damage matrix file as a 3D plot. MCLF actually loads the Plot 3D module MP3D for this type of display.
Damage analysis
Display both the cycles and damage matrices on a single 2-D plot. MCLF actually loads the Cycles and Damage Postprocessor module Single Location S-N Analysis - (MSLF), 1033.
Hysteresis loops
If the hysteresis loops were saved during a single shot analysis (as a .slp file), they may be displayed using the module Two Parameter Display program, MTPD. See (Cycle/Damage Histogram Display (MP3D), 320.
The Results Listing option will list the full results of the current life estimation in tabular form. Such listings are carried out within MCLF. If parameters have been changed but not Recalculated, then the non-recalculated data will NOT be listed. Selecting this will load the Cycles File Listing program Cycle and Damage Analysis - (MCDA), 1061 module.
Figure 13‑37 Sample MCLF Plots
Environment Keywords
MCLF makes the following entries in the local user environment.
 
USERNAME
Username
.FBJ
Last job file
PFSTSUNI
Material units
BACKTOLR
Back life calculation tolerance
MATCHECK
Default status of material checking
FATAUTOV
Default status for auto-overwrite
.DAC
Last .dac file
$SIGNAL
Last single parameter file
$CYCLES
Last cycles file
$HISTOG
Last histogram file
.CYH
Last cycles histogram file
$PAIRED
Last X-Y file
$ANNOT1
The first annotation string; $ANNOT2 TO $ANNOT6 also available.
Batch Operation
It is recommended that, by default, the /OV=Y keyword be included in every batch command line, since if it is omitted and an output file with the specified name already exists, batch operation will cease. To finish an MCLF batch line use /OPT=X to exit from the postprocessing screen.
When batch processing with a series of different inputs, it is necessary to use a new batch line and option definition for each new input. The new line must specify the option from the postprocessing menu into which the new input will go. For example, when using the jobfile fatjob.fbj.
mclf /job=fatjob.fbj/inp=datafil1.dac/opt=l
mclf /job=fatjob.fbj/inp=datafil2.dac/opt=l/opt=g/kf=2.0
mclf /job=fatjob.fbj/inp=datafil3.dac/opt=l/kf=2.5/opt=g
Omitting the /OPT keywords will cause the batch file to fail because inputs without /OPT keywords cannot be loaded and will therefore be ignored (the values in fatjob.fbj will be used instead). Each run of MCLF with one or more new parameters requires a new batch line. It is permissible to input more than one parameter on a batch line, but they must be different. Note also that the order in which the batch keywords appear is not critical.
Note that if a MCLF job file exists as the result of a prior interactive run of MCLF, then its job settings can be overridden in batch by use of the appropriate postprocessing option and the appropriate parameter. For example, suppose a job file called life.fbj exists in which Kf is set to 2. The following batch line will NOT change Kf.
mclf /job=life/kf=4/ov=y
However, the following batch line WILL change KF and automatically recalculate a new life...
mclf /job=life/opt=g/kf=4/ov=y 
because /OPT=G invokes the Geometry option in which the change is made.
MCLF keywords:
 
/JOB
Job File Name
/CREate
Confirm Creation of New Job Y,N
/CALFIL
Nature of the Calibration File A,B,N
/CALNAMe
Name of Calibration File
/LUNIts
Input Units of Calibration files
/STATE
Strain State A,P
/STYPE
Strain Type M,E
/INPut
Name of the Input Loading File
/TYPE
Type of Loading Input T,C,R
/UNITs
Internal Loading Units M,K,U
/EQUNITs
Equivalent Units
/NUMEQUnits
Number of Equivalent Units
/STArt
Start Time for Analysis
/END
End Time for Analysis
/FACTor
Scale Factor for input Loading
/OFFset
Offset of Input Loading
/GATE
Hysteresis Gate of Analysis
/AMPlitude
Magnitude of Constant Amplitude
/MEAN
Mean of Constant Amplitude
/MATENTry
Mode of Material Parameter Entry L,E,G
/MATSRC
Source of materials data S,U
/DBNAME
Material Database Name
/MATname
Material Parameter Dataset Name
/EDIT
Edit Material Dataset Y,N Parameter Editing & Entry
/UTS
Ultimate Tensile Strength
/YM
Young's Modulus
/SF
Fatigue Strength Coefficient
/BASQ
Fatigue Strength Exponent
/EF
Fatigue Ductility Coefficient
/COFF
Fatigue Ductility Exponent
/NP
Cyclic Hardening Exponent
/KP
Cyclic Hardening Coefficient
/CUTOFF
Endurance Limit Cut-off
/SERRE
Elastic Standard Error
/SERRP
Plastic Standard Error
/SERRC
Cyclic Standard Error
/RATIO
R - Ratio
/SURFace
Surface Finish (=POLished, GRound, GOod Machined, Average Machined, POOrly Machined, HOt Rolled, Forged, Cast, Water Corroded, Sea Corroded, User Defined.)
/TREATment
Surface treatment (=None, Nitrided, Cold rolled, Shot peened, All)
Parameter Generation:
/GENTYP
Generic Material Type S,A,T,O
/UTS
Ultimate Tensile Strength/
SERR
Standard Error of Log strain
/RAREA
Reduction in Area Calculation Parameters
/DESign
Design Criterion Percent
/MSC
Mean Stress Correction Method N,S,M,A
/MINERs
Value of Miner' Constant
/EPCORR
Elastic-Plastic Correction Method, Neuber or Mertens-Dittmann N,M
/ALPHAP
Shape Factor for Mertens-Dittmann
/GEOTYPe
Notch Geometry E,C
/KF
Fatigue Strength Reduction Factor
/KT
Elastic Stress Concentration
/NOTCH
Notch Root Radius
/ADDKF
Additional Kf
/OUTput
Generic Name for Output Files
/CYCles file
Whether a Cycles File is Required Y,N
/DAMage file
Whether a Damage File is Required Y,N
/DAMUNI
Units of the Damage Matrix A,P,N
/XYFILe
Save X-Y Data in a File Y,N
/HTYPE
Matrix Type I,N
/SIZE
Matrix Size
/LIMit type
Matrix Limits A,U
/RMIN
Minimum Range of Matrix
/RMAX
Maximum Range of Matrix
/MMIN
Minimum Mean of Matrix
/MMAX
Minimum Mean of Matrix
/OPTion
Postprocessing Options L,M,S,G,O,D J,P,C,R
/RESOPTion
Results Display Options R,X
/JOBOPTion
Job File Options N,S,L
/PRFOPTion
Preference Options M,B,U
/UNIOPTion
Units Options MP,P,K,N,MN
/NEWJOB
Start Another Job Y,N
/LIFE
Life required for Back Calculation
/MATCHK
Material Parameter Checking Y,N
/TOLER
Sensitivity of Back Calculation
/OVerwrite
Overwrite Existing Output Files Y,N
/AUTOVerwrite
Overwrite Without Confirmation Y,N
/SWTMTH
S-W-T algorithm method F,I
/PLOt
Whether hardcopy is required Y,N
/PLTNAM
Hardcopy file name
Cycle and Damage Analysis - (MCDA)
MCDA calculates and displays cycles and damage distributions so that different test conditions may be compared and the reasons for variations in fatigue damage may be determined. Displays may be as histograms, continuous curves, or exceedance plots.
The MCDA module provides a means of displaying cycles histograms created from Rainflow analysis, and damage histograms created from Fatigue analysis. The input data is “histogrammed” within a two dimensional array with a maximum of 128 x 128 elements (bins). MCDA takes each array dimension and sums the data for each element across its opposing dimension.
This creates two new 2 dimensional histograms, each with a single array with a maximum of 128 elements. Exceedance data is also calculated for each new array. This is achieved by summing the data values from the current element in the array to its last element. This is repeated for each element until the maximum element is reached for that array.
An example of this calculation for this is shown in the following table.
 
TOTALS ARRAY
 
 
 
 
 
element
1
2
3
4
5
 
34.5
72.45
123.2
-12.0
312.0
EXCEEDANCE ARRAY
530.15
495.65
423.2
300.0
312.0
Module Operation
The MCDA module can be run in one of the following three ways:
From the Advanced Fatigue Utilities pulldown menu under Tools | MSC.Fatigue (for Patran) or under Tools | Fatigue Utilities (for Pre & Post)
In Stand alone mode by typing mcda
By incorporating the MCDA commands in a batch operation
Once running, MCDA will display the following window.
Figure 13‑38 Naming the Input Cycle and Damage Files
The user is asked to enter the cycles histogram file name which usually has a .cyh extension. If a damage histogram file is found with the same generic name as the cycles histogram file this is also loaded. A default file may already exist in the cycles histogram field.
A second cycles histogram file may be loaded. If the user does not want to load a second histogram file, then this field can be left blank.
Depending on the user's input, one of four menus will be shown. These menus give a list of the available plot options for the histogram files selected.
 
Option
Description
Plot Cycles Histogram 1
Plots only the cycles of the first file selected.
Plot Cycles Histogram 2
Plots only the cycles of the second file selected.
Plot Both Histograms
Plots the cycles from both files together in the same plot for comparison purposes. This option is only available when two files have been supplied.
Plot Damage File 1
Plots the damage from the corresponding cycles of the first file only. This option is only available when a corresponding damage file exists in conjunction with the cycles plot.
Plot Damage File 2
Plots the damage from the corresponding cycles of the second file only. This option is only available when a corresponding damage file exists in conjunction with the cycles plot.
Plot Both Damage Files
Plots damage from both files. This option is only available when two files have been supplied.
Plot Damage/Cycles - File 1
Plots cycles with the corresponding damage superimposed on top of the cycles plot for the first file which is useful for viewing cumulative damage.
Plot Damage/ Cycles - File 2
Plots cycles with the corresponding damage superimposed on top of the cycles plot for the second file.
When the input cycles and/or damage files have been named, and a menu option chosen, then a plot of the data is displayed. An example plot is shown below in Figure 13‑39 (in this case a plot of a cycles file and it's corresponding damage file).
Figure 13‑39 A Typical MCDA Plot
Once a plot is on the screen, operation of the interface is from the command line or via the pull down menus. The menu system is in MCDA is very similar to that in other graphical modules in MSC.Fatigue, many of which are explained in Plot an Entry Option, 217 in the Loading (PTIME) module. Each menu item can also be invoked form the command line above the graphical display. Some of the command line codes are:
SA, NE, HC, RE, EX, PL,JO, TO, FU, WX, RA, ME, EP, TP, CW,
DW, LC, NC, LD, ND, GR, TI, TOUT, TIN, ZON, ZOF, AT, DT,
RON, ROFF, HBON, HBOF, GT, PESA, PEDE, PEPR, PEDA, PETX,
PEAX, PEAN, PEGR, PEBA, PEER, PESU, PEMF, PEMT, PEMO, PEMB,
PEMH, PEMK, XMIN, XMAX, CMIN, CMAX, DMIN, DMAX, CU, OP,
OPDM.
Typing OP at the command line will list all the options available within MCDA. Those of particular interest to MCDA are explained below.
 
Save Files
SA
Saves the displayed histograms as a single file.
New File(s)
NE
Allows a new input file to be entered.
Range Plot
RA
Displays the range of the histogram along the X-axis.
Mean Plot
ME
Mean Plot, displays the mean of the histogram along the X-axis.
Log Cycles
LC
Displays the cycles on the Y-axis on a logarithmic scale.
Linear Cycles
NC
Linear (Normal) Cycles values along the Y-axis (not log scale).
Log Damage
LD
Displays the damage plot Y-axis as a log scale.
Linear Damage
ND
Linear (Normal) Damage values on the Y-axis.
Exceed. Plot
EP
Displays the exceedance plot of the histogram.
Totals Plot
TP
Displays the total histogram along the X-axis
X Window
XW
Sets a specific X minimum and Y
Cycle Window
CW
sets a specific cycle minimum or maximum to plot.
Damage Window
DW
Sets a specific damage minimum and maximum to plot.
CMIN/MAX
 
Sets the minimum and maximum Y-axis cycles file window to plot (functionally similar to CW above).
DMIN/MAX
 
Sets the minimum and maximum Y-axis damage file window to plot (functionally similar to DW above)
When the cursor is activated the following sub options are available:
V or Left Hand Mouse Button -
 
Pick off a data value
W
 
Window on X-axis
Q
 
Quit cursor mode
TOUT
 
Ticks drawn on the outside of the box
TI
 
Ticks drawn on the inside of the box
CP
 
Change plot type, returns to the menu
HC =<filename>
 
(file name optional)
XMIN/XMAX=<Value>
 
Set range or mean limits on the x-axis
CMIN/CMAX=<Value>
 
Set cycle limits on the cycles-axis
DMIN/DMAX=<Value>
 
Set damage limits on the damage-axis
When saved, the following extensions are given to the various signal files.
 
.cdc
Cycles histogram as totals plot.
.cdd
Damage histogram as totals plot.
.exc
Cycles histogram as exceedance plot.
.exd
Damage histogram as exceedance plot.
Batch operation
MCDA runs in all the standard batch modes supported in MSC.Fatigue
A list of MCDA’s batch keywords:
 
INP1
Name of the cycles histogram file
/INP1=SAETRN
INP2
Name of the second cycles histogram file
/NP1=SAETRN2
DOPT
The number of the chosen display option menu
 
OPT
The number of the chosen graphics menu option
/OPT=3
XMIN
The minimum X-axis value
/XMIN=100
XMAX
The minimum Y-axis value
/XMAX=1E4
CMIN
The minimum cycles value to be displayed
/CMIN=10
CMAX
The maximum cycles value to be displayed
/CMAX=1000
DMIN
The minimum damage value to be displayed
/DMIN=5
DMAX
The maximum damage value to be displayed
/DMAX=275
OV
Overwrite an existing file Yes/No
/OV=Y
PLTNAM
Plot the file name (used with /OPT=HC)
/PLTNAM=FILENAME
PTIT
Plot the file title (used with /OPT=HC)
/PTIT=TEST RUN 5
A typical batch command line would be:
mcda /inp1=data1.cyh/inp2=data2.cyh/dopt=2/pltnam=mytest /ptit=test run 12/ov=y
In this case, Histogram files data 1 and data 2 will be loaded. If both files have matching damage histogram files then these will also be loaded. The user has specified plot option 2 on the option menu, the command SA is given, and this saves the plotted histogram as a signal data file. The data file already exists therefore the OV=Y batch command gives permission to overwrite it. The file name will be mytest.cyh with a title of Test Run 12.
Cycles File Lister - (MCYL)
It sometimes becomes necessary to examine the contents of a MSC.Fatigue cycles file. In such instances, MCYL can be used to numerically list the contents of such a file, either to the screen or to a list file stored on disk. MCYL can also display a summary of the information resident in the file header region.
MCYL also accesses the cycle results files generated by the fatigue analyzers FEFAT, MCLF and MSLF and create a rainflow matrix of cycles according to user specified engineering units and limits. It can also display the histogram, alphanumerically, and produce an output histogram file which can itself be either plotted, listed or edited.
MCYL can display paired data files and three parameter cycles matrix files. It can also modify such files and save them as a disk file.
The 3-D rainflow matrices can be formed in terms of nominal or local stress or strain, with cycles being classified into a maximum of 128 range classes and 128 mean classes. The size, in terms of physical units, of the range and mean classes can be set independently.
The distribution of fatigue cycles in terms of counts or damage can be displayed alphanumerically or saved for later plotting by the MP3D module.
Although a histogram with 64 columns and 64 rows cannot be displayed on the screen as a unity, windows of 8 columns wide and 8 rows high can be used to scan the entire matrix. The particular use of this module lies in its ability to display quantitatively the relationship between numbers of specific cycles and associated damage content.
The cycle matrices generated can be used directly as inputs to the matrix fatigue analyzers FEFAT, MCLF and MSLF. This feature is particularly useful if the original time series data files are large and it is undesirable to process them directly.
Module Operation
MCYL can be run in one of 3 ways:
From the Advanced Fatigue Utilities pulldown menu under Tools | MSC.Fatigue (for Patran) or under Tools | Fatigue Utilities (for Pre & Post).
In stand alone mode by typing mcyl the system prompt
By incorporating the MCYL commands in batch mode
The main menu items of MCYL are:
List a cycles file - List the contents of a cycles file (.cyl) to screen or disk.
Form a cycles matrix - Create a cycles matrix and possibly a damage file (.cyh and .dhh)
List a cycles matrix - List to screen or disk a file of the type created in 2 above
List to EXCEL - Create a text format data file in Lotus Excel spreadsheet format (.txt)
List a Cycles file
To list a cycles file the following input is requested:
 
Option
Description
Input File Name
When this option's mask is first run only the Input File Name field is displayed. The user must tell MCYL the name and location of the cycles file to list. This file must be a standard cycles file from the fatigue analysis section or from the signal classification section.
By default, MCYL expects to find any input data files to be resident in the user’s directory. Probably the easiest method of entering input file names is to use the pick list facility. This also enables other drives/directories to be accessed.
If a file name is entered without an extension then the default extension .clf will be given to the file name entered. A default file name may also be given in the question window.
When the Input File Name field is filled the other fields become active. They are explained below.
Listing
In a critical location analysis, results are produced for the nominal location, and at the critical (local) location. Because of limited listing space, only one of these sets of results may be listed at one time. Therefore select either 1 or 2.
Gate Value (also applies to Damage Gate)
A gate may have originally been applied during the analysis to limit the calculation to large cycles only (setting a gate value is a method of reducing signal noise). It is possible to increase the original value with a higher gate value to further limit the listing. The gate must be a range value in the units of the file listing. For example in a stressed based file the gate value should be in MPa, whereas for strain based the units should be uE.
Display Type
The cycles may be shown in Max/Min format (where the peak and trough values of the cycles are displayed) or Range/Mean (where the range is the distance between max and min and the mean the average of the max and min.) Enter the value 1 or 2. Alternatively, the strings MAX and RANGE are also recognized.
Output Destination
The cycles file data may be displayed at the user’s terminal by selecting S for Screen, or written out to a list file by selecting F for file.
If File is selected then an additional Output File Name field must be filled. The default output file name is that of the input file but with a .lst extension. The default file name can be edited by the user (to avoid overwriting an existing file for example).
Output File Name
Enter a file name to which the data should be sent. The default extension for the file is .lst (see Output Destination above).
The output file contains header information and a complete listing of the data in the cycles file.
Form a Cycles Matrix
To form a cycles matrix, the following input is required.
 
Option
Description
Input File Name
A cycles file from FEFAT, MCLF or MSLF should be input here. A damage histogram input field is also available (MCYL knows the source of the input file by reading it's header). The damage histogram field is optional.
Generic Output Name
Type the name of the file (or files if a damage file is also to be created). The default is to copy the Input File Name although this may require the input file to be overwritten.
Cycles Matrix Type
MCYL is able to form up a range-mean matrix from a cycles results file in terms of either stress or strain. Toggle the appropriate option into the field.
MCYL will then display the limits of the largest and smallest cycles present in the cycles results file and prompt for the following:
Minimum Range Limit
For the purpose of scaling the histogram the range of the smallest cycle to be represented in the histogram must be entered in physical units (usually microstrain). If there are any cycles smaller than the minimum range specified, then those cycles will be excluded from the histogram. However, a warning message will appear and a note made in the note book.
Maximum Range Limit
For the purpose of scaling the histogram the range of the largest cycle to be represented in the histogram must be entered in physical units (usually microstrain). If there are any cycles larger than the maximum range specified, then those cycles will be excluded from the histogram. However, a warning message will appear and a note made in the note book.
Number of Columns
For the purpose of scaling the histogram it is possible here to specify the number of classes (bins) into which to classify the cycle means. Any integer number up to a maximum of 128 (the default) may be entered.
Number of Rows
For the purpose of scaling the histogram it is possible to specify the number of classes (bins) into which to classify the cycle ranges. Any integer number up to a maximum of 128 (the default) may be entered.
Minimum Mean Limit
For the purpose of scaling the histogram the smallest mean value to be represented in the histogram must be entered in physical units (usually microstrain). If there are any cycles whose mean values are smaller than the value specified, then those cycles will be excluded from the histogram. However, a warning message will appear and a note made in the note book.
Maximum Mean Limit
For the purpose of scaling the histogram the largest mean value to be represented in the histogram must be entered in physical units (usually microstrain). If there are any cycles whose mean values are greater than the value specified, then those cycles will be excluded from the histogram. However, a warning message will appear and a note made in the note book.
List a Cycles Matrix
A common usage for this option is to list the cycles file created in the above option although an existing file can also be listed. This option can list BOTH Cycles and Damage files. The following input is required:
 
Option
Description
Cycles File Name
Specify a cycles histogram file in this field, for example one generated in the Form a Cycles Matrix option. The default extension is .cyh but other compatible file types can be typed with their extension. This field may be left blank if only a damage histogram file is to be listed.
Damage File Name
Specify a damage histogram file in this field, for example one generated in the Form a Cycles Matrix option. The default extension is .dhh. This field may be left blank if no damage histogram file is to be listed.
List Zero Bins
List Zero Bins = No, will filter out from the listing any data entries that contain zero cycles (and therefore contribute nothing to the analysis). If this is set to NO it will ONLY apply to the cycles matrix NOT a damage matrix, should one be included in the processing.
List Type
3D is a normal 3D histogram plot, 2D = Range plots the sum of the X-axis values, 2D = Mean plots the sum of the Y-axis values.
Bin Location
The matrix files hold values in mean or range bins. The maximum of the bins can be used for the listing, or the mean of the bins (mean is (maximum-minimum) /2).
Damage Gate
Setting a gate at any value will filter out any data entries with a value LESS than the gate. Leaving this field blank will filter out nothing.
Destination - Screen or File
If the input file(s) are to be listed to screen select Screen. To save them to disk select File. They will be saved in the current directory.
List to EXCEL
This main menu suboption will save the listings file in a format that can be imported into a Microsoft Excel spreadsheet. The following input is required:
 
Option
Description
Input File Name
This field should contain the name of the cycles file that is to be converted to Excel text (.txt) format and saved on to disk.
Output File Name
By default this is the same as the Input File Name not with a .txt extension. However any valid name and extension can be specified here.
Output Format
The program can create two types of file. In the first case, all the data is written to the file, including header and label information. In the Raw Data option, only the matrix data is written.
Label Data
The data is normally output to the tab separated file without labels and totals. To add labels and totals to the data, answer Yes to this question.
Batch Operation
MCYL can be run in macro mode. In this mode of operation simple listings can be automatically generated. Please refer to the 'batch operation' section for more general details of invoking modules in batch.
 
/INPut
The name of the input cycles file. /INP=SAETRN
/LOCation
Whether the nominal or critical location is to be used. /LOC=2
/GATe=
The gate value to limit the listing. /GAT=50
/DISTYPe
The required display format. /DISTYP=2
/DESTination
The destination of the output. /DEST=F
/OUTput
The name of the output list file. /OUT=CYCLES
/OVerwrite
Overwrite existing files, Yes or No. /OV=Y
/DAMage
Damage gat. /DAM=12
/HSTOPT
Cycles matrix type. /HSTOPT=
/RMIN
Minimum range limit. /RMIN=10
/RMAX
Maximum range limit. /RMAX=8000
/NCOL
Number of columns. /NCOL=32
/NROW
Number of rows. /NROW=64
/MMIN
Minimum mean limit. /MMIN=200
/MMAX
Maximum mean limit. /MMAX=3000
/DMAT
Damage matrix, Y or N. /DMAT=Y
/DAMSC
Damage units Actual, %, or Normalized. /DAMSC=%
/OPT
Main option, 1, 2, 3, 4. /OPT=3
/CYH
Cycles histogram file name. /CYH=TEST1.CYH
/DHH
Damage histogram file name. /DHH=TEST1.DHH
/ZERO
List zero bins. /ZERO=YES
/TYPE
List type - 3 (3D),R (2D range), M (2D mean). /TYPE=2DR
/BINLOC
Bin location, Mean or Range. /BINLOC=R
/DGAT
Damage gate. /DGAT=20
Time Correlated Damage - (MTCD)
MTCD is a fatigue analyzer that can be used to pin-point fatigue damage within a loading history. It uses the local stress-strain approach to track local stresses and strains by means of a single-pass algorithm. An estimate of the total damage accrued by one pass through the load history is made and displayed graphically.
The local stress strain approach can be used to estimate the time taken to generate an engineering crack 2-5 mm in length.
The methodology needs a description of the loading history, the component geometry and material properties.
Typically, the loading history is measured in the field, and is assumed to be representative of the actual loading the component will experience throughout it's life. Life estimates are usually expressed in the form of a number of repeats of that history to failure, i.e. that the history essentially repeats itself. This assumption allows the analysis to be simplified.
Because its local stress-strain coordinates must lie on the cyclic stress strain curve, analysis starts at the largest absolute strain excursion, continues to the end of the sequence, wraps around to the start, and finishes at the largest excursion again. In this way all cycles are closed and repeatable. This procedure is often referred to as the two-pass algorithm, one pass to locate the largest excursion, and a second pass to carry out the fatigue analysis.
The single pass algorithm commences analysis at the beginning of the loading sequence and accumulates damage as each cycle closes and each reversal is replaced by larger relatives at the head of the rainflow stack. At the end of the analysis, the largest strain excursion will be at the head of the stack and accompanied by a number of residual peaks and valleys which cannot be closed.
The local stress and strain are tracked at each strain excursion, by using the cyclic stress strain relationship, together with a rheological material model using segment exhaustion.
Once a cycle or appropriate reversal has been identified, the fatigue damage is estimated and ascribed equally to both of its turning points. The damage is written in the correct sequential position of the output damage file. Loading data values which are not turning points, are written out to the damage file with zero damage. In this way the time-base is maintained and the two files may be compared directly. The number of cycles, unclosed reversals, and the total damage accumulated, are presented for scrutiny.
It is important to note that MCLF and FEFAT both use a two pass algorithm, and when analyzing the same loading sequence it will provide total damage values slightly different to those given by MTCD which commences analysis at the first point in the sequence. Naturally, MTCD will agree with the other analyzers when MTCD is also forced to start at the largest excursion.
Module Operation
The MTCD module can be run in one of the following three ways:
From the Advanced Fatigue Utilities pulldown menu under Tools | MSC.Fatigue (for Patran) or under Tools | Fatigue Utilities (for Pre & Post).
In stand alone mode by typing mtcd at the system prompt
By incorporating the MTCD commands in a batch operation
When run in interactive mode, MTCD's first screen will ask for the name of the file to process and looks like this:
Figure 13‑40 The First MTCD Screen
The user must enter the name of an Input Job File, which has a .fjb extension. If the name of an existing Job File is entered, it's parameters will be loaded and MTCD will go straight to a postprocessing screen. If a new job is specified then its parameters have to be entered in a series of screens. If no name is entered then the results of processing may NOT be saved.
The operation of this module is very similar and in many cases identical to MCLF, MSLF, and FEFAT. It is assumed that the user has a working knowledge of FEFAT and therefore only those items specific to MTCD is explained here.
Figure 13‑41 illustrates the major routes through MTCD.
Figure 13‑41 The General Module Structure (MTCD)
The above flowchart is mirrored by the options that are on the Postprocessing menu. If a new job is being defined, then the following input is required:
The Loading Environment
This information is identical to that needed for MCLF. See Service Loading Environment, 1046.
Model Parameters
This information is identical to that needed for MCLF. See Model Parameters, 1051.
Material Data Input
This information is identical to that needed for MCLF. See Material Data Input, 1051.
Geometry
This information is identical to that needed for MCLF. See Geometry Screen, 1052.
Results Setup
This is the only input that is somewhat different.
 
Option
Description
Output File
Enter the name of the output file. The default extension is .dam. This file is in .dac format.
Output File Type
Output damage files can have either of two formats. In the first, the single value format, the absolute damage associated with each turning point, half for each cycle or reversal, is written to the output file at the same point in time it occupied in the time series file. Non turning points have zero damage ascribed to them. In the second format, the damage is accumulated as it occurs and so provides insight into the rate of damage accumulation.
Start At
MTCD uses a single pass algorithm to accumulate fatigue damage. As a result, analysis can commence at the beginning of the loading sequence, instead of at the largest excursion, and so provide a more accurate distribution of damage within the time series.
For compatibility with MCLF and FEFAT, MTCD has been provided with the option to commence analysis at the largest absolute strain excursion. When run in this mode, MTCD will provide values of total damage similar to those calculated by MCLF, if not, the values will be slightly different.
When all of the data for a calculation has been entered MTCD will create the required damage file. Results will also be listed to the screen in the first instance. Plots can be displayed from the Postprocessing menu.
Note that the result is presented as accumulated damage rather than repeats to failure.
The Postprocessing Main Menu
This menu is identical to that needed for MCLF. See The Postprocessing Menu, 1056.
 
Note:  
If any parameters are changed the Recalculate option must be run for the changes to take effect.
This display of results is of the most recently calculated life estimation. Exactly what is available for display depends upon the calculation; if an X-Y file was not created then it cannot be displayed, a multiple calculation will not produce any histogram files, etc.
Figure 13‑42 Sample MTCD Plots. Top: Job Details Page,
Bottom: A Cumulative Damage Plot, an Instantaneous Damage Plot
Batch Keyword Summary
A sample batch line is shown below:
mtcd  /job=test1/opt=l/inp=test101/ov=y/opt=r/opt=d/resopt=t
/pltnam=test101
In this example, the time series contained in file test101.dac will be processed according to the defaults set in job file test1.fjb and the resulting damage distribution will be plotted together with the input time series and save in a plot file call test101.plt.
Note that if a MTCD job file exists as the result of a prior interactive run of MTCD, then its job settings can be overridden in batch by use of the appropriate postprocessing option and the appropriate parameter. For example, suppose a job file called life.fbj exists in which Kf is set to 2. The following batch line will NOT change Kf.
mtcd /job=life/kf=4/ov=y
However the following batch line WILL change Kf and automatically recalculate a new life...
mtcd /job=life/opt=g/kf=4/ov=y 
...because OPT=G invokes the Geometry option in which the change is made.
A list of MTCD’s batch keywords:
 
/JOB
Job File Name
/CREate
Confirm Creation of New Job Y,N
/INPut
Name of the Input Loading File
/CALFIL
Nature of the Calibration File A,B,N
/CALNAMe
Name of Calibration File
/LUNIts
Input Units of Calibration files
/STATE
Strain State A,P
/FACTor
Scale Factor for input Loading
/OFFset
Offset of Input Loading
/GATE
Hysteresis Gate of Analysis
/EQUNIts
Equivalent Units
/NUMEQUnits
Number of Equivalent Units
/MATENTry
Mode of Material Parameter Entry L,E,G
/MATname
Material Parameter Dataset Name
/EDIT
Edit Material Dataset Y,N
/PLTNAM.
Request a hardcopy plot of the results file, and give it a file name. /PLTNAM=MYTEST.PLT
Parameter Editing & Entry
/UTS
Ultimate Tensile Strength
/YM
Young's Modulus
/SF
Fatigue Strength Coefficient
/BASQ
Fatigue Strength Exponent
/EF
Fatigue Ductility Coefficient
/COFF
Fatigue Ductility Exponent
/NP
Cyclic Hardening Exponent
/KP
Cyclic Hardening Coefficient
/CUTOFF
Endurance Limit Cut-off
/SERR
Standard Error of Log Reversals
/RATIO
R - Ratio
Parameter Generation
/GENTYP
Generic Material Type S,A,T,O
/UTS
Ultimate Tensile Strength
/SERR
Standard Error of Log Reversals
/RAREA
Reduction in Area, %
Time Correlated Damage Analysis
/SURFace
Surface Finish: Polished, Ground, GOod Machined, Average Machined, Poorly Machined, Hot Rolled, Forged, Cast, Water Corroded, Sea Corroded, User Defined. SUR=HOT ROLLED
/TREATment
Surface treatment, None, Nitrided, Cold rolled, Shot peened. /TREAT=NONE,/TREAT=SHOT PEENED
/DESign
Design Criterion Percent
/MSC
Mean Stress Correction Method N,S,M
/MINERs
Value of Miner' Constant
/GEOTYPe
Notch Geometry E,C
/KF
Fatigue Strength Reduction Factor
/KT
Elastic Stress Concentration
/NOTCH
Notch Root Radius
/ADDKF
Additional Kf.
/OUTput
Generic Name for Output Files
/OTYPE
Damage File Type S,C
/ANAStart
Analysis Start Position B,L
/OPTion
Postprocessing options L,M,S,G,O,D,J,P,C,R, X, (i.e. the menu hot key)
/RESOPTion
Results Display options T,X, (T= plot time series)
/JOBOPTion
Job File Options N,S,L
/PRFOPTion
Preference Options M,B,U
/UNIOPTion
Units Options MP,P,K,N,MN
/NEWJOB
Start Another Job Y,N
/MATCHK
Material Parameter Checking Y,N
/OVerwrite
Overwrite Existing Output Files Y,N
/AUTOVerwrite
Overwrite Without Confirmation Y,N
Single Location Vibration Fatigue - (MFLF)
MFLF is a single location, stress-based fatigue analysis module that accepts stress response PSDFs as input. This module has also been mentioned in an earlier chapter. As an example of usage copy over the original SAE history saetrn.dac to your working directory. This signal is assumed to contain a stress time response.
Use MASD to convert the time signal into the frequency domain by converting it to a PSDF. See the section on MASD in this chapter for instruction on how to do this. Use all the default settings. The output file name should be saetrn.psd.
1. Invoke MFLF from the system prompt by typing mflf or choose the Single Location Vibration Fatigue option from the Advanced Fatigue Utilities pulldown menu under Tools | MSC.Fatigue (for Patran) or under Tools | Fatigue Utilities (for Pre & Post).
2. Accept all defaults for all setup screens except for these: Input Filename: saetrn.psd; Dataset Name: MANTEN
The analysis will proceed, the results will be presented and eventually you will be placed in the Post Processing Options. Answer Yes to any overwrite permission questions.
Go to Display results... | Cycles histogram.
Exit from MFLF when you are finished.
 
Note:  
This example is for illustration purposes only. The signal used in this example is not actually an appropriate signal to use in that it is not truly random or gaussian as required by a random vibration fatigue analysis.
See Frequency Fatigue Life Estimation (MFLF), 656 for a more detailed description of this utility.
Stress-Strain Analysis - (MSSA)
Stress-Strain Analysis processes rosetta data and finite element data from MSC.Fatigue, including software strain gauges. It creates outputs suitable for use by either the stress or strain-life fatigue analyzers. It also provides an indication of the state of multiaxiality present, suggests possible processing routines through the fatigue analyzers and has a multiaxial fatigue analyzer that works by using a MSC.Fatigue .fes file. In addition to this, the module can be used to convert elastic-plastic strain records, measured on one material, to that of another material. It can also convert elastic-plastic strain records to equivalent fully elastic ones and vice-versa.
 
Note:  
See Stress-Strain Analysis (MSSA), 864 for a more detailed description of this utility.
Multi-Axial Life Analysis - (MMLF)
MMLF is a single location multiaxial fatigue analyzer based on Crack Initiation and has been briefly referred to in a previous chapter. It requires three strain input signals which typically come from strain gauge rosettes. For rectangular rosettes the signals are separated by 45 degrees. For delta rosettes the signals are separated by 60 degrees.
As an example, take the three SAE histories that we have been using thus far (saetrn.dac, saesus.dac, saebrakt.dac), except run them through MLEN and chop them all to 1800 seconds. (See the previous section on MLEN to learn how to do this.) We will assume that these new signals are from a rectangular rosette.
1. Invoke MMLF from the system prompt by typing mmlf or choose the Multi-Axial Life Analysis option from the Advanced Fatigue Utilities pulldown menu under Tools | MSC.Fatigue (for Patran) or under Tools | Fatigue Utilities (for Pre & Post).
2. Enter a new job name such as “mlf_example.” It is new, so answer Yes to the ensuing question.
3. Accept all defaults for all setup screens except for these: Gauge 1: saetrn.dac; Gauge 2: saesus.dac; Gauge3:saebrakt.dac;Material Name: MANTEN
4. The analysis will proceed, the results will be presented and eventually you will be placed in the Post Processing Options. Answer Yes to any overwrite permission questions.
Go to Display results | Stress and Strain. Plot this result and any of the others you wish in this menu selection.
Exit from MMLF when you are finished.
Note:  
Strain signals input to MMLF are assumed to be elastic-plastic. No elastic-plastic corrections are performed in MMLF. Use MSSA and/or SSG to do this if necessary from FE data.
See Local Multiaxial Stress/Strain Fatigue Analyzer (MMLF), 406 for a more detailed description of this utility.
Crack Growth Data Analysis - (MFCG)
MFCG calculates the Paris Law coefficient, C, and exponent, m, in the expression da/dN = C(ΔK)m from actual raw test data obtained under constant amplitude loading conditions.
 
Note:  
See Crack Growth Data Analysis (MFCG), 558 for a more detailed description of this utility.
Kt/Kf Evaluation - (MKTAN)
MKTAN stores and retrieves values for stress concentration factor (Kt) solutions for geometric details, and calculates Kt and Kf. It allows users without finite element analysis (FEA) software rapid and convenient access to Kt values for a range of common component geometries. The Kt values can be used in programs such as MTCD to predict the fatigue life of an engineering component which require the user to input a value for stress concentration factor Kt, or fatigue strength reduction factor Kf. Such values have been calculated for a wide range of shapes (geometries) and sizes of engineering components and are available in standard reference works such as Peterson’s book on Stress Concentration Factors.
Tables exist for geometries such as elliptical holes with a range of long and short diameters, in plates of various widths, crankshafts, springs, keyways, inclusions, etc. MKTAN stores these values in a library of cases and allows the user easy access to the libraries for calculation purposes.
The library cases cover popular and common geometries such as holes and notches in plates and bars, plus effects of surface condition on crack initiation, and strength reduction Kf values for various environments such as seawater.
Subsequent releases of MKTAN will contain progressively more comprehensive cases for a wider range of geometries and conditions. Library entries supplied with MKTAN are detailed in an index file called secure.ktd. Actual entries are held in a secure database. Supplied files cannot be edited. However the user can copy entries into a user database and edit them at will. Details of the user database are held in a file called user.ktd.
Module Operation
MKTAN can be run in one of the following 3 ways:
From the Advanced Fatigue Utilities pulldown menu under Tools | MSC.Fatigue (for Patran) or under Tools | Fatigue Utilities (for Pre & Post).
In stand alone mode by typing, mktan at the system prompt
By incorporating the MKTAN commands in a batch operation.
There are two main operations that MKTAN performs:
Calculate a Kt value from the Secure or User database.
Edit the User database or view the Secure or User databases.
There are a variety of steps and options to both of the above operations. However, both types of operation are started from MKTAN’s main menu. The main menu screen is the first screen to appear when MKTAN is operated in interactive mode. The main menu screen is shown overleaf.
Figure 13‑43 The MKTAN Main Menu Screen
The options available from the main menu screen are illustrated in the flowchart below.
Figure 13‑44 Flowchart Summarizing MKTAN Menu System
The options on the left of the flowchart allow for user database functions such as display or edit. Entries from the secure database can also be copied to the user database and then edited although the secure database cannot be changed.
The options on the right of the flowchart enable the component geometry to be selected, and the exact dimensions of that geometry, plus any other information needed to calculate a Kt value to be input.
Database Functions Menu
All database functions are achieved via this menu. The text below details the purpose and function of each of the options from the Database Functions selection on the main menu.
Add an Entry
Choose this option when an entry to the database is being made. The user will be sent to a screen which has empty fields into which a definition of the entry will be made.
 
Option
Description
Description field
Enter a description for the database entry. The description can NOT be left blank.
Comments field
Enter some comments about the database entry. The comments field can be left blank.
The Reference field
Enter a reference for the database entry (the Reference field). The reference can be left blank.
Name of Storefile
This is the name of the file where the database information will be kept. The name of the store file must be entered, and must be unique.
X type
The X parameter type can be toggled between Single and Ratio by pressing the space bar or clicking the left mouse button. The X parameter type Single means: a single variable (numerator), e.g. A, such as the width of a plate.
An example of a X parameter type Ratio:
A / B, such as the long and short radii of an elliptical hole.
X Scale
This scale refers to the lookup table X scale. The X scale can be either Linear or Log 10. The X scale can be toggled between Linear and Log 10 by pressing the space bar or clicking the left mouse button.
Family Type
The Family type can be Single, Ratio or None. Each of these values can be chosen by toggling the type, by pressing the space bar, or by clicking the left mouse button.
The family type Single refers to a single variable representing the family value (e.g. A). The family type Ratio refers to two variables representing the family value as a ratio (e.g. A / B). The family type None means that there are no variables which represent the family value. This means that there is only one curve (lookup table) in the family.
Variable 1 - 4
The variables entered are used to represent the X parameter and/or Family parameter.
Geometry type
The available geometries can be toggled through and selected.
When the fields have been filled the 2nd Add Entry screen is displayed. Some of the fields will NOT be shown if they are not appropriate to the parameter and choices specified on the previous screen.
A second Add an Entry screen will be presented whose input parameters are:
 
Option
Description
X Parameter numerator
The available X parameter variables can be shown/selected by pressing the space bar or clicking the left mouse button. Ensure that this selection is for the numerator for the X-axis ratio, for example a in a/b.
X Parameter denominator
The available X parameter variables can be shown/selected by pressing the space bar or clicking the left mouse button. Ensure that this selection is for the numerator for the X-axis ratio, for example b in a/b.
Family parameter numerator
The available family parameter variables can be shown/selected by pressing the space bar or clicking the left mouse button. Ensure that this solution is for the numerator family parameter ratio, for example r in r/D.
Family parameter denominator
The available family parameter variables can be shown/selected by pressing the space bar or clicking the left mouse button. Ensure that this solution is for the denominator family parameter ratio, for example D in r/D.
Plot File Name
This field is where the picture/plot entry is named. The default file type is .plt. The plot file should contain an image of the Geometry to be used in the calculation of Kt. The image will be shown if the geometry is selected.
Lookup tables
If the type chosen is .mdf (MSC.Fatigue two parameter file) or ASCII the lookup table file name is specified here. If the lookup table type is polynomial then the polynomial constants and limits are required to be entered. The format of this file is shown after this table.
Lookup File Name
This screen allows the name of the lookup table to be entered.
Select database screen (geometry type)
This screen allows the database to use for drawing the pictures (geometries) to be selected.
Polynomial constant screen
A screen appears if Polynomial was selected. Enter the value for the polynomial constant A0 to A3. n is from 1 to 4 and all 4 constants should be entered even if they are all zero.
The Family Parameter values:
For each family (sub-set) the value of the family should be entered, for example A=0.1. For each subset the family parameter value must be larger or smaller than the previous one (uniformly increasing or decreasing).
Format of MKTAN ASCII lookup files:
If the lookup table type is ASCII then the file type is defaulted to .asc (e.g. entering fred is interpreted as fred.asc). An ASCII file can be created using any editor or word processor, however the format provided by MKTAN is as follows. The first line of the ASCII file must contain the following words starting in column 1: KTAN ASCII FILE.
The second line must contain the number of families specified in this file, e.g. 3. The format is then:
The family value for the lookup table
The number of lookup table pairs
The lookup table x, y pairs (each pair on separate lines)
An example of an ASCII file is as follows:
 	KTAN ASCII FILE	<ASCII file identifier>
2 <number of families (2 shown below)>
0.1 <family value for family 1>
6 <number of lookup table x, y pairs>
10.0,20.0 <X,Y pairs>
30.0,30.0
50.0,35.0
60.0,40.0
70.0,80.0
80.0,90.0
0.2 <family value for family 2>
3 <number of lookup table x, y pairs>
8.0,15.0 <x,y pairs>
10.0,25.0
20.0,100.0
 
Note:  
Items in < > are for reference only, and do not appear in the file.
Delete entry
This question relates to the deletion (removal from database) of a user database entry. The Storefile associated with the user database entry is also deleted. After selecting an entry to be deleted, you must confirm the deletion by answering in an affirmative manner (Yes) to the Are you Sure? prompt to delete the entry. Answering Negatively (No) will not delete the user entry. The database entry and the user database will be removed if this question is answered in an affirmative manner (Yes).
Answering No will leave the User Database without making changes. If the user database is deleted (removed) then no user database operations will be allowed until further entries are made to the user database (i.e. by completing an ‘Add an entry’ operation).
Edit an Entry
This screen allows the editing of a User Database entry. At first this option lists all the database entries. An entry must be selected for editing. Note that a page of information on the currently highlighted entry can be obtained by pressing the Info button. The Info data is there to help users choose. When a selection has been made another menu appears. The following explains what each menu option does.
:
Option
Description
Edit general details
This allows the description, comments, reference and geometry type to be changed.
Replace Plot File
This allows a new plot file (geometry drawing) to replace the existing geometry drawing.
Extract to MDF file
This allows the extraction of the lookup table data to a .mdf format (paired) file. Polynomial lookup table cannot be extracted.
Extract to ASCII file
This allows the extraction of the lookup table data to an ASCII format file. The ASCII file produced is the same format as required to be input to MKTAN to represent a lookup table. Polynomial lookup table cannot be extracted.
Replace Lookup table with MDF
This replaces the existing lookup table with an .mdf format file.
Replace Lookup table with ASCII -
This replaces the existing lookup table with an ASCII format file.
Edit Polynomial constants
This allows the editing of the polynomial constants lookup table
Show Entries Screen
This screen allows the user to view the database entries. It contains these suboptions:
 
Option
Description
Show all entries
The complete database is listed. Details of individual entries are stored as pages of general information. To view a page of information about an entry move the highlight bar over the entry and click on Info or press F3. Alternatively a semi-sorted list of database entries can be viewed by using the sub-option below.
List by Geometry Type
This screen shows a list of the database entries with a given geometry type. Entries are displayed in pages with general information displayed about each entry. Note that a page of information on the currently highlighted entry can be obtained by pressing or by clicking on the Info button. The Info data is there to aid users in their choice.
Pictures
The final option on the Database Functions menu is Pictures. All database entries should have a corresponding picture associated with them (specified on the Add Entry form). The picture shows the user what the dimensions are and what shape the component is. The pictures will be produced on a graphics package and will be a plot file with a .plt extension. When ’Pictures’ is selected, the user is given a list of available geometry types. Selecting a geometry type, which may have several cases, leads to a page of pictures.
Figure 13‑45 A Kt Picture (This Example is a Crankshaft)
The Calculate Menu
The other option from the Main Menu is Calculate. This allows Kt values to be calculated for any geometry contained within the database.
When Calculate is selected, the user must choose to use either the Secure database or the User Database. This choice is made on a pop up menu that appears next to the main menu. There then follows an established series of steps that lead to a Kt value being calculated. When the database is chosen a form appears.
It is here that the geometry type of the component being analyzed is chosen from the database of geometry types. After the geometry type is selected a list of entries of that type is displayed. An entry must be selected. Any single geometry type will probably contain more than 1 entry or case. For example holes in a plate of finite width, and holes in a plate of infinite width. One of them must be selected before Kt can be calculated.
Selection is by one of two methods, either:
From the list shown on a screen such as the screen overleaf where the user can move the highlight bar over the desired choice and select it by pressing ENTER or by pointing and clicking the mouse pointer over the selection.
or
The user can click on the Picture button to produce a picture of the case. In the above example it will cause the picture over the page to be displayed. One picture is of a plate with a finite width of value w. The other picture is of a plate with an infinite width. A selection can be made by pointing and clicking on the appropriate picture.
When selected, a screen like this will appear:
Figure 13‑46 Kt Hole Dimension Definition
The picture defines the relevant dimensions of the geometry and gives guidance to the user as to what numbers should be entered where. All the dimensions and variable names etc. were defined when the entry into the database was made using the Database Functions/add Entry facility.
The menu to the right of the picture contains the Calculate command. Clicking on Calculate causes MKTAN to ask the user to input the actual values for the dimensions. Note the value for Kt (in this case 4.333).
The graphics menu (shown overleaf) also contains the hardcopy command so users can record the case, with its dimensions, and the calculated Kt value for reporting purposes.
Graphics Mode Operation
Some of the graphics commands of MKTAN are shown here. These commands can be entered in the command line of the graphics window or accessed directly from one of the pulldown menus:
CA, ED, NG, HC, PL, EX, RON, ROFF, PESA, PEDA, PETX, PEAX, PEAN, PEGR, PEBA, PEER, PESU, PEMF, PEMT, PEMO, PEMB, PEMH, PEMK, OP, HBON, HBOF, CU.
The graphics screens are menu or command line operated. Most of the options are standard MSC.Fatigue operations and are explained in Graphical Display, 226. Options of particular interest to MKTAN are explained below.
 
Edit
ED
Allows a second calculation to be performed with new (edited) values. Note that Calculate must be clicked upon before the new values are acted upon.
Calculate
CA
Triggers the process that calculates new K values. The user must supply values for whatever variables have been defined for the current geometry.
New Geom
 
This option sends the user back to the Select Geometry Type screen.
Main Menu
Sends the user back to the MKTAN Main Menu screen.
Batch Operation
A list of MKTAN’s batch keywords:
\
/MEN
Main menu option. (E = Exit, D = Database Menu, C = Calculate)
/DB
Database menu option. (A = Add, E = Edit, etc.)
/CAL
Calculate menu option. (U = User database, S = Secure database)
/SE
Show entry menu option. (L = List by type, S = Show all entries)
/EDT
Edit menu option. (number of option, e.g. 1 is Edit general)
Database menu options
Add an entry batch keywords (also Edit entry keywords where applicable)
/DES
Description of entry
/COM
Comments about the entry
/REF
Reference
/STF
Storefile name (unique)
/XTYP
The type of X parameter required. (S - Single, R - Ratio)
/XSC
The type of X lookup table scaling. (Li - Linear, Lo - Log 10)
/FAM
The type of Family parameter. (S - Single, R - Ratio, N - None)
/VAR1
Variable 1 name (e.g. A)
/VAR2
Variable 2 name (e.g. B)
/VAR3
Variable 3 name (e.g. C)
/VAR4
Variable 4 name (e.g. D)
/GEOM
Geometry name (e.g. Holes)
/XP1
X parameter numerator
/XP2
X parameter denominator
/FP1
Family parameter numerator
/FP2
Family parameter denominator
/PLT
Plot File name
/LUT
Lookup table type (M - MDF, A - ASCII, P - Polynomial)
/LUF
Lookup file name
MDF lookup file add entry
/FVn
Family value, where n represents the set number, and can be 1 to 10. (e.g. /FV1 = 0.5 for family value 1)
Polynomial lookup file add entry
/FVn
Family value, where n represents the set number, and can be 1 to 10. (e.g./FV1 = 0.5 for family value 1)
/XMINn
The minimum X value for the lookup table (n is set number)
/XMAXn
The maximum X value for the lookup table (n is set number) |
/CnA0
The first polynomial constant (n is set number)
/CnA1
The second polynomial constant (n is set number)
/CnA2
The third polynomial constant (n is set number)
/CnA3
The fourth polynomial constant (n is set number)
Database menu options
Delete an entry
/ENT
The entry to delete (the first occurrence found of the entry will be used, when the full entry specification is not given)
/DEL
Confirmation required to delete entry (Y - Yes, N - No)
/KIL
Confirmation required to remove the user database (Y - Yes, N - No). This situation occurs when deleting the last entry in the user database, this will cause the user database to be removed as well as the entry. Selecting No will not delete the entry or database.
Edit entry menu options
Edit general details - keywords same as add entry
/NPLT
Replace Plot File. The new plot file name.
/NMDF
Extract to MDF file. The file name of the output MDF file.
/NMDF
Extract to ASCII file. The file name of the output ASCII file.
Replace Lookup tables with MDF
/LUF
The file name of the MDF format lookup file.
/FVn
Family values for each set (n is set number)
Replace Lookup tables with ASCII
/LUF
The file name of the ASCII format lookup file Edit
Polynomial constants - same as Add entry Polynomial lookup table
Database menu option
Pictures - not applicable in batch mode as the option draws geometry to screen.
Calculate Menu
/GTYP
The geometry type to list (use geometry type number)
/ENT
The geometry entry to use in the calculation of Kt