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How can you use simulation to predict steel member fatigue life?

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Steel members are essential components of many structures, such as bridges, buildings, and towers. However, they are also subject to cyclic loading, which can cause fatigue damage and reduce their service life. How can you use simulation to predict steel member fatigue life and avoid costly failures? In this article, you will learn about the basic concepts of fatigue analysis, the types of simulation methods available, and the benefits and challenges of using simulation for steel member design.

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Vimal Kumar

FIMarE, CEng, MRINA, DTM l Lead Structure Specialist | Naval Architect |
Alex Oudovikine

Doctor of Philosophy - PhD at USSR and CANADA. Author of 42 patents and 40 publications, Founder of STEDAX Inc…
Rajeev Devaraj

PhD candidate at USC Australia │ Structural Engineering

1 Fatigue analysis basics

Fatigue analysis is the process of evaluating the resistance of a material or a structure to cyclic loading, which can cause cracks to initiate and propagate until failure. Fatigue analysis involves three main steps: defining the loading history, characterizing the material behavior, and applying a fatigue criterion. The loading history describes the magnitude, frequency, and sequence of the applied stresses or strains. The material behavior describes how the material responds to the loading history, such as its elastic, plastic, or viscoplastic properties. The fatigue criterion defines the conditions for crack initiation and growth, such as the stress-life, strain-life, or fracture mechanics approaches.

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Alex Oudovikine

Doctor of Philosophy - PhD at USSR and CANADA. Author of 42 patents and 40 publications, Founder of STEDAX Inc. AUTODESK Autorized Developer
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Simulation is non-scientific, fortune-telling approach so it is absolutely useless for accurate fatigue analysis; when results of analysis directly correlate with physical test results. Simulation is useless as a subject for discussion. The criterion of truth is a practice.

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2 Simulation methods

Simulation is a powerful tool for performing fatigue analysis, as it can capture the complex interactions between the loading history, the material behavior, and the fatigue criterion. There are two main types of simulation methods for fatigue analysis: deterministic and probabilistic. Deterministic methods assume that the loading history, the material behavior, and the fatigue criterion are known and fixed, and they provide a single value for the fatigue life or the fatigue damage. Probabilistic methods account for the uncertainties and variabilities in the loading history, the material behavior, and the fatigue criterion, and they provide a distribution or a probability for the fatigue life or the fatigue damage.

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Vimal Kumar

FIMarE, CEng, MRINA, DTM l Lead Structure Specialist | Naval Architect |
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The Stress-Life (S-N) Approach is a common method in the marine industry that uses S-N curves to predict the fatigue life of steel under different stress levels. This method shows how the applied stress amplitudes and the number of cycles to failure are related, giving useful information about the fatigue behavior of steel components.

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3 Benefits of simulation

Simulation offers several benefits for predicting steel member fatigue life, such as the ability to handle complex geometries, loading conditions, and boundary conditions that are difficult to replicate in experiments or analytical solutions. Additionally, it can provide detailed information on the stress and strain distributions, crack locations and sizes, and damage evolution in the steel members. Simulation can also support design optimization, sensitivity analysis, and reliability assessment by varying the input parameters and evaluating the output responses. Finally, it can reduce the time and cost of testing and inspection by providing virtual prototypes and predictions.

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Vimal Kumar

FIMarE, CEng, MRINA, DTM l Lead Structure Specialist | Naval Architect |
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Predicting the fatigue life of marine structures in a precise way is still a challenging task. Primarily because of uncertainty in defining the loading history. In general, a simplified fatigue approach is applied which is easier to predict and at the same time cost-effective. It is well-defined in most of the classification societies' rules. It uses a range of stress based on loading history and the S-N curve for the material. There are numerous benefits of such practice: To a great extent, the approach identifies the fatigue life of the structure. It can help to identify the fatigue life of the complete hull and same time, it helps to identify the critical areas where fatigue-related crack is prone to initiate.

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4 Challenges of simulation

Simulation can present some difficulties when attempting to predict steel member fatigue life. Accurate and reliable data on the loading history, material behavior, and fatigue criterion may be hard to come by or could be influenced by measurement errors or environmental factors. Similarly, complex and nonlinear models may require a great deal of computational power and skill to run and validate. Additionally, simulation may not take into consideration residual stresses, corrosion, weld defects, or fatigue interactions, which can all have an effect on the fatigue performance of steel members. Lastly, it may not account for the variability and uncertainty in the simulation inputs and outputs that can affect the accuracy of the results.

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5 Tips for using simulation

Using simulation to predict steel member fatigue life can be effective, so long as you define the objective and scope of the simulation, such as the design criteria, failure modes, and performance indicators. Additionally, it’s important to choose the appropriate simulation method, model, and software that suit your objective, scope, and available data. You should also validate and calibrate your simulation model and results with experimental data or analytical solutions, checking for errors or inconsistencies. Lastly, it’s essential to interpret and communicate your simulation results clearly and transparently, while acknowledging the limitations, assumptions, and uncertainties involved.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Rajeev Devaraj

PhD candidate at USC Australia │ Structural Engineering
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While standard fatigue models for many materials are available in simulation software, it is often beneficial to conduct experimental studies on the material itself to observe its behaviour under various fatigue scenarios. This additional data can be used to refine the simulation model and make it more accurate.

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How can you use simulation to predict steel member fatigue life?

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6

1 Fatigue analysis basics

2 Simulation methods

3 Benefits of simulation

4 Challenges of simulation

5 Tips for using simulation

6 Here’s what else to consider

Structural Engineering

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How can you use simulation to predict steel member fatigue life?

1

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3

4

5

6

1 Fatigue analysis basics

2 Simulation methods

3 Benefits of simulation

4 Challenges of simulation

5 Tips for using simulation

6 Here’s what else to consider

Structural Engineering

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