13 Congresso Ibero-americano de Engenharia Mecnica

13 Congreso Iberoamericano de Ingeniera Mecnica

Lisboa, Portugal, 23-26 de Outubro de 2017

A COMPARISON AMONG METHODOLOGIES FOR FATIGUE LIFE CALCULATION

IN TIME AND FREQUENCY DOMAIN WITH APPLICATION IN THE DYNAMIC
SIMULATION

Julian Marcell Enzveiler Marques1, Rogrio Jos Marczak2

1. Department of Mechanical Engineering, Universidade Federal do Rio Grande do Sul, Porto Alegre, Brasil, email:
julian.marcell@ufrgs.br
2. Department of Mechanical Engineering, Universidade Federal do Rio Grande do Sul, Porto Alegre, Brasil, email:
rato@mecanica.ufrgs.br

Abstract

Currently, the industry demand for the construction of complex structures is a consequence of a fierce
competition in the semi-trailer market. Computational tools support, based on the Finite Element
Method, enable to size these kinds of structures submitted to random loads varying, based on time.
In this case, it is common to perform dynamic simulations in the time domain using Finite Element
(FE) model of the plate or beam, and thus obtain the critical stresses acting at the point of interest.
The present work proposes a comparison among methodologies, which are able to estimate the fatigue
life in the time and frequency domain in a simple case of a cantilever beam. The different Finite
Element models and methods of calculating fatigue life in the frequency domain are compared using
the classic calculation method as a reference (fatigue life in the time domain). The methodology takes
into account the different excitations at the base of the cantilever beam. The excitations are based on
the road surface profile according to International Standard Organization (ISO). The comparison is
made not only with the following analyses: modal, harmonic, transient, spectral, but also with
computational routines. Thus, the engineer can select meshes, with a viable amount of degrees of
freedom, and spectral methods enabling dynamic simulations, i.e. when analyzing industrial complex
structures. However, some methods for estimating fatigue life in the frequency domain did not
provide reliable results mainly with beam elements.

Keywords: Fatigue Life, Time and Frequency Domain, Finite Element Method, Dynamic
Simulation, Plate and Beam Element
 XIII CIBEM 2017 Lisboa
1. Introduction
The use of numerical models in Finite Element (FE)
analysis predicts the performance and reliability of
industrial complex structures. On the other hand, in
several situations, such prediction is difficult to
obtain, because many parameters are relevant and
compromise the results considerably.
In view of these challenges, the use of the correct
FE model allows stresses analysis and predicts the
fatigue life of structures in order to minimize
simulation time.
The general objective of this work is to propose a
comparison among methodologies capable of
estimating the fatigue life in the time and frequency
domain in a simple case of a cantilever beam. The
different FE models and fatigue life calculation
methods, in the frequency domain, are compared
using the classic calculation method as reference
(fatigue life in the time domain). This comparison is
supposed to be used to the develop vehicles with the
aiming of reducing products weight and increasing
robustness and reliability.
The specific objective of this study case (simple
case of a cantilever beam) is to apply road
excitations, according to ISO 8608 [1].
1.1. Fatigue Life Estimation in the Time Domain
The traditional approach uses the time domain to
estimate the fatigue life of the components. The
most famous researcher of fatigue in the time
domain was August Whler [2]. He contributed a lot
to engineers through the S-N curve in the late 18th
century.
Over the years, some methodologies have been
developed to consider mean stress effect. The first
researcher in this area was Johann Gottfried
Heinrich Gerber in 1874, soon after in 1899,
Goodman [3] and finally, Soderberg. They studied
and determined the influence of the mean stresses in
fatigue life considering the yield strength, the
ultimate tensile strength, and the fatigue strength
coefficient.
Palmgren, 1924, and Miner, 1954, developed the
concept of damage accumulation named in their
honor as the Palmgren-Miner Rule [4], widely used
so far.
Coffin and Manson, 1954, raised important
considerations about low-cycle fatigue, plastic
deformation effects in each cycle. They brought up
S-N curves, which make a relation between the
deformation and the number of cycles. This became
known as Coffin-Manson relation.
In order to evaluate the fatigue life of a structure
subject to complex loading and allow the
application of Palmgren-Miner Rule, an algorithm
was developed by Endo and Matsuishi, 1968, called
the Rainflow, a cycle counting method. Among
several methods of counting cycles studied, Endo
and Matsuishi method performs better than most of
the other methods.
1.2. Fatigue Life Estimation in the Frequency
Domain
In 1954 Rice [5] set foundations for frequency
domain fatigue which has been used until today.
One of them showed that the probability density
function (pdf) of peaks for a narrow-band signal
tended towards a Rayleigh distribution. His research
also presented the cycle counting and the
irregularity factor of the moments of Power Spectral
Density (PSD). Later, in 1964 Bendat [6] proposed
a significant step towards a method for determining
fatigue life from PSDs. He showed that the
probability density function (pdf) of peaks for a
narrow-band signal also approximates a Rayleigh
distribution as the bandwidth reduced. In addition to
it, each peak of stress ranges is followed by a valley
of equal amplitude. Thus, the PDF of peaks is the
same as the PDF of stress ranges. To complete his
method, Bendat used a series of equations based on
Rice to estimate the expected number of peaks used
in spectral moments of the area under the PSD. In
the 1980s, researchers Wirsching and Light, 1980,
Chaudhury and Dover, 1985, Ortiz and Chen, 1987,
developed models to deal with the conservatism of
the Narrow Band solution in applications in the
offshore industry [7-9]. The equations proposed by
Chaudhury and Dover are presented in form of
equivalent stresses, whereas the Wirsching equation
presents a multiplying factor for the Narrow Band
equation. This solution is applicable in several
industrial problems situations. Dirlik in 1985 [10]
based on Bendat [6] evaluated the cycles counting
through the spectral moments under the PSD curve.
The method is empirical and has a good
approximation of fatigue life. To develop this
method Monte Carlo techniques were used. Dirliks
model is the most used nowadays and has been
considered the best model when compared with
other ones. In 1988, Bishop [11] presented a
relevant study using methods to obtain PSD cycle
counting. He concluded that structures with many
input and output data of the system and various
information in Frequency Response Function (FRF)
have better results in frequency domain. Halfpenny
in 1999 [12] used the Narrow-Band and Dirlik
methods to estimate the fatigue life of a simple case,
pointing out that the model proposed by Dirlik is the
most robust before the traditional method of cycle
counting method (Rainflow). Halfpenny also
 XIII CIBEM 2017 Lisboa

suggests the use of frequency domain methods to
minimize simulation time.
Mrnik, Slavi and Boltear in 2013 [13] verified
that the Benasciutti and Tovo method [14] provides
the best life estimates for real cases of dynamic
structures such as wind turbines. The exceptions are
the cases of the automotive industry, where the
Zhao and Baker method [15] presented better
results. This article concludes that, in addition to
Dirlik's approach, Benasciutti and Tovo, and Zhao
and Baker methods can be used for estimating
fatigue life in the frequency domain.
Larsen and Irvine in 2015 [16] showed the
importance of random processes for real cases such
as offshore and aerospace structures. They brought
up the Narrow-Band damage approach and included
the estimations of Wirsching and Light, Ortiz and
Chen and other spectral methods. Finally, small
differences between spectral methods and fatigue
life, in the time domain, were found with some
limitations. The aim of the guidelines obtained in
this work is to increase confidence in estimating
fatigue life.
freedom system determines the size of the matrices
and vectors needed to the equations of the problem.
Thus, the FE model discretization is fundamental to
minimize simulation time and capture accurate
responses.
The discretization of the present work is obtained
based on the theory of finite element method
(FEM). Therefore, the first discretization of the
cantilever beam is made with plate elements, which
is suitable for analyzing thin plates of structures.
Figure 1 illustrates the finite element (FE) mesh of
the cantilever beam with plate elements. It reached
80 elements, 289 nodes and 1680 degrees of
freedom.

2. Computational Procedure
Figure 1: Cantilever beam mesh with plate elements.
This study case consists of analyzing a cantilever
beam (2x100x500 mm, thickness, width and In the second mesh, Figure 2, beam elements were
length). This analysis was made through used for the same cantilever beam.
commercial software of FE [17] where the stress as When applied beam elements to a cantilever beam
a function of time and response of PSD were reached 20 elements, 61 nodes and 240 degrees of
obtained. Excitation calculations, used as input data freedom.
for numerical simulations, and fatigue life
calculations were implemented in a commercial
compiler [18]. The structural models of the
cantilever beam studied are numerical models of the
plate and beam. Hypotheses for the excitations are
assumed in order to reach the objectives of the
work:
The excitations at the base of the cantilever
beam, are based on the road surface profile from
ISO 8608 [1];
The displacement PSD is defined not only in Figure 2: Cantilever beam mesh with beam elements.
accordance with road classes A, B and C, but
also speed of 30 and 60 [km/h]; The dynamic system response starts from the
The road displacement signal based on time is motion equation that is composed of 3 matrices with
obtained the equation from Shinozuka and Jan [19]; degrees of freedom according to the EF model. In
The transient dynamic analysis of this cantilever the case studied, the nonlinear effects are not
beam is used for fatigue calculations in the time important and the system of equations is reduced so
domain. The displacement signal, based on time, that minimizes simulation time.
obtained by the displacement PSD is used as input
data. Similarly, the displacement PSD and modal q (t) + q (t) + q(t) = f(t) (1)
analysis are input data to determine the response of
PSD. Finally, the fatigue life calculation in the where is the mass matrix, is the damping
frequency domain is performed. This sequence of matrix, is the stiffness matrix, q(t) is the vector
dynamic analysis and calculation routines are of degrees of freedom and f(t) is the excitation force
applied in both structural models. The degrees-of- vector.

The excitations of the cantilever beam are in the
base. Thus, the cantilever beam with plate elements
is excited at 9 nodes and beam elements at 1 node.
The displacements imposed are the same in both
cases.
The matrices and vectors of the motion equation can
be partitioned to represent the free degrees of
freedom, ql (t) and the restricted degrees of
freedom, qr (t). The Eq. (1) is rewritten in the matrix
form as flow:
ll lr q l (t) lr q l (t)
[ ][ ] + [ ll ][ ] Timoshenko beam theory.
rl rr q r (t) rl rr q r (t)
lr ql (t) 0
+ [ ll ][ ]=[ ] of two comparable dimensions and another with
rl rr qr (t) fr (t)
where fr (t) corresponds to the reactive forces in the
restricted degrees of freedom due to the imposed
displacements.
The null vector appears because the absence of
forces acting on the free nodes [17]. A different
equation can be found when rewriting Eq. (2)
without the null vector:
ll q l (t) + ll q l (t) + ll ql (t) = fefe (t)
where fefe (t) is the vector of the effective load due
to imposed displacements.
In 2005 Hougaz [20] proposed that the effective
loading vector of the road surface profile can be
represented without the damping in the restricted
degrees of freedom:
fefe (t) = lr q r (t) + lr qr (t)
In the same way, Morsch in 2001 [21] proposed in
his model a formulation that uses the independent
movement of each node. It induces a problem of the
quasi-static type that can be adopted due to the
displacement of the base. However, inertial forces
are neglected because the vehicle starts moving
after stable equilibrium conditions are satisfied. If
these conditions are not considered, the vehicle will
initially travel with a residual vertical acceleration
that is not supported by the Mass-Spring-Damper
System. Therefore, the analysis is done around the
initial static equilibrium point and the
displacements are referenced to point of
equilibrium.
Thus, when the inertial forces are neglected and Eq.
(3) with Eq. (4) are linked, the general equation is
found:
ll q l (t) + ll q l (t) + ll ql (t) = lr qr (t)
XIII CIBEM 2017 Lisboa
Finally, the mathematical formulation Eq. (5) shows
the free and restricted degrees of freedoms for the
study case of this work.
2.1. Structural models
It is common select plate elements to perform linear
static stress analysis and beam elements for
dynamic analysis. The two classical structural
theories are used in the simulations of this case to
determine fatigue life:
Mindlin-Reissner hypotheses for the plate.
(2) The plate elements used in this work are composed
lower magnitude. Only its medium surface can
consider this semi-thick plate. According to Ansys
[17] plate element has 8 nodes with 6 degrees of
freedom each: translation and rotation in the X, Y
and Z axes.
The beam elements are three-dimensional bar
elements, being suitable for the analysis of
structures that have thicknesses. It considers the
shear deformation and rotational bending effects. It
is a quadratic beam element with 3 nodes, in each
(3) node there are 6 degrees of freedom [17].
2.2. Materials properties
The material is linear elastic, isotropic and small
displacements. The mechanical properties of the
material are used as input data in all analyses and
calculation routines.
Table 1 shows the mechanical properties of
(4) structural steel.
Table 1: Mechanical properties of structural steel
Minimum yield strength 2.5E+2 MPa
Ultimate tensile strength 4.6E+2 MPa
Young's modulus 2.0E+5 MPa
Poisson 0.3
Density 7.85E+3 kg/m
Typical values of low carbon steel are observed and
it is classified as a common structural steel in
industry. However, it is based on the American
Society for Testing and Materials (ASTM) standard
that guarantees the minimum yield strength.
The structural steel parameters of the S-N curve
from the tests performed by Higashida, Burk and
Lawrence [22] are used in this work, Table 2.
Table 2: Structural steel parameters of the S-N curve
Fatigue strength coefficient 1014 MPa
Fatigue strength exponent -0.132
Slope of the S-N curve 7.576
(5)
 XIII CIBEM 2017 Lisboa
2.3. Displacement PSD
The random, stationary, ergonomic and Gaussian
process is described completely with a single
autocorrelation function. Such characteristics
ensure that in any position of time and space, the
spectrum representing the road surface profile is
always the same.
The displacement PSD used in the base of the
cantilever beam is classified as A, B and C [1].
The speed of the cantilever beam is considered as a
constant and different values are studied, v = 30
km/h and 60 km/h. The reference spatial frequency,
n0 = 0.1 cycles/m, constant-velocity PSD, w = 2,
spatial frequency range, n = 0.011 cycles/m, 2.83
cycles/m and geometric mean (Gd(n0) = 16 x 10-6
m, 64 x 10-6 m and 256 x 10-6 m) are used to
calculate the displacement PSD.
The road displacement signal based on time is
obtained after the displacement PSD calculations as
described above. Shinozuka and Jan [1] propose the
method used.
Munari, Fontanella, Hoss and Marczak [23]
recommends using 20 cosines or more to stabilize
the Root Mean Square, RMS, the exponent of the
fitted PSD calculated on Gd, w, and the geometric
mean, Gd(n0).
In the same way, they suggest simulations with road
surface profiles greater than 4000 meters assuring a
random, stationary, ergonomic and Gaussian
process.
The frequency rate of the displacement signal is
calculated in order to avoid Aliasing problems and
respect the Nyquist theorem. From this, the
sampling frequency is set at 400 Hz.
2.4. Dynamic analyses
The dynamic response system of the cantilever
beam is obtained close to the fixed end at which it
exhibits higher stresses, Figure 3 and Figure 4. It is
the critical point for the plate and beam model. The
response is given in terms of von Mises stress.
CRITICAL POINT
Figure 3: Critical point of the cantilever beam with plate
elements.
CRITICAL POINT
Figure 4: Critical point of the cantilever beam with beam
elements.
The Software used uses the Newmark method for
numerical integration as standard. The method can
be understood as an extension of the linear
acceleration method and was originally proposed as
a form of unconditional stability for the constant
mean acceleration method, also known as the
trapezoid rule [24].
2.5. Frequency-domain methods
First, spectral moments is calculated because they
are quantitative and essential parameters. After, the
damage and fatigue life is determined by the Narrow
Band method, Dirlik, Wirsching and Light, Ortiz
and Chen, Benasciutti and Tovo, and Zhao and
Baker.
The methods described here are concerned with the
stationary Gaussian process. It is further divided
into narrowband and wideband processes. While the
Narrow Band approximation is only appropriate for
narrowband processes, others are also appropriate
for wideband loading processes [13].
In order to limit the level of PDF stress of the
methods studied, the Bishop form [11] is used:
= 220 (6)
where, is the upper limit of integration, proposed
according to Eq. (6) and 0 is the 0th spectral moment.
3. Results
The cantilever beam is a hypothetical model, not
necessarily a vehicle, which aims to eliminate a
geometric complexity of the analysis. Thus, it
makes more comparisons in the numerical models
composed of FE of different levels in a structural
complexity. In this way, it is trying to concentrate
the errors in the models of fatigue life.
The Narrow Band, Dirlik, Wirsching and Light,
Ortiz and Chen empirical and semi-empirical
methods, Benasciutti and Tovo, and Zhao and
 XIII CIBEM 2017 Lisboa

Baker, calculate the fatigue life, Table 3 and Table Narrow Band Dirlik
4, in the time and frequency domain. Wirsching and Light Ortiz and Chen
The various fatigue life results in the frequency
Benasciutti and Tovo Zhao and Baker
domain are compared assuming as reference the 20
result of fatigue life in the time domain.
18
Table 3: Fatigue life of cantilever beam with plate elements.
The value in parentheses indicates the relative error. 16

Road Class A B C
14
Speed 30 km/h 60 km/h 30 km/h 60 km/h 30 km/h 60 km/h
12
Rainflow

RELATIVE ERROR
4.4E+09 2.1E+09 3.7E+07 1.5E+07 1.4E+06 3.9E+05
[km] 10
Narrow 3.1E+10 1.7E+09 1.6E+08 8.7E+06 8.3E+05 4.6E+04
Band [km] (5.92) (-0.21) (3.29) (-0.43) (-0.40) (-0.88) 8

Dirlik 7.5E+09 7.7E+08 7.9E+07 8.0E+06 8.3E+05 8.4E+04 6

[km] (0.71) (-0.64) (1.12) (-0.47) (-0.40) (-0.78)
4
Wirsching
4.5E+10 2.5E+09 2.4E+08 1.3E+07 1.2E+06 6.8E+04
and Light
(9.23) (0.17) (5.33) (-0.15) (-0.11) (-0.83) 2
[km]
Ortiz and 2.7E+10 2.1E+09 1.4E+08 1.1E+07 7.5E+05 5.8E+04 0
Chen [km] (5.19) (0.00) (2.85) (-0.27) (-0.46) (-0.85)
-2
Benasciutti
3.4E+10 2.4E+09 1.8E+08 1.2E+07 9.3E+05 6.5E+04 CLASS CLASS CLASS CLASS CLASS CLASS
and Tovo A 30 A 60 B 30 B 60 C 30 C 60
(6.73) (0.12) (3.80) (-0.18) (-0.32) (-0.83) KM/H KM/H KM/H KM/H KM/H KM/H
[km]
Zhao and Figure 5: Relative error in cantilever beam with plate
9.1E+10 5.9E+09 4.7E+08 3.1E+07 2.5E+06 1.6E+05 elements.
Baker
(19.52) (1.78) (11.75) (1.02) (0.80) (-0.59)
[km]
Note that Dirlik has the smallest differences, Zhao
It is observed that the Dirlik method is the most and Baker the largest, as commented earlier. The
robust in general, with results close to fatigue life in highest error values are at speed of 30 km/h, where
the time domain, calculated through Rainflow cycle all spectral methods have a longer fatigue life
counting. Verifying the mean of the relative errors compared to fatigue life in the time domain. The
of Dirlik, have 8% difference, much average smaller opposite occurs in road class C with speed of 60
than the other spectral methods. km/h, the fatigue life values of the spectral methods
It is found a fatigue life value equal to the time are smaller.
domain by the Ortiz and Chen method with road
class A and speed of 60 km/h. This method has in Table 4: Fatigue life of cantilever beam with beam elements.
The value in parentheses indicates the relative error.
its formulation an empirical factor to correct the
Road Class A B C
Narrow Band method.
Ortiz and Chen use PSD moments that vary Speed 30 km/h 60 km/h 30 km/h 60 km/h 30 km/h 60 km/h
according to the material slope. The method Rainflow
4.4E+09 2.1E+09 3.7E+07 1.5E+07 1.4E+06 3.9E+05
proposed by Zhao and Baker presents great [km]
discrepancies, for example, road class A with speed Narrow 3.1E+10 1.7E+09 1.6E+08 8.7E+06 8.3E+05 4.6E+04
of 30 km/h is 19.52 times greater than the fatigue Band [km] (5.92) (-0.21) (3.29) (-0.43) (-0.40) (-0.88)
life in the time domain. Although it is a recently Dirlik 7.5E+09 7.7E+08 7.9E+07 8.0E+06 8.3E+05 8.4E+04
proposed and semi-empirical method, the errors [km] (0.71) (-0.64) (1.12) (-0.47) (-0.40) (-0.78)
related to time domain are high values, except road Wirsching
4.5E+10 2.5E+09 2.4E+08 1.3E+07 1.2E+06 6.8E+04
class C with speed of 30 and 60 km/h. and Light
(9.23) (0.17) (5.33) (-0.15) (-0.11) (-0.83)
The graph of Figure 5 shows the relative error [km]
variations according to road class and speed. Ortiz and 2.7E+10 2.1E+09 1.4E+08 1.1E+07 7.5E+05 5.8E+04
Chen [km] (5.19) (0.00) (2.85) (-0.27) (-0.46) (-0.85)
Benasciutti
3.4E+10 2.4E+09 1.8E+08 1.2E+07 9.3E+05 6.5E+04
and Tovo
(6.73) (0.12) (3.80) (-0.18) (-0.32) (-0.83)
[km]
Zhao and
9.1E+10 5.9E+09 4.7E+08 3.1E+07 2.5E+06 1.6E+05
Baker
(19.52) (1.78) (11.75) (1.02) (0.80) (-0.59)
[km]
 XIII CIBEM 2017 Lisboa

Dirlik method remains the most robust and reliable errors of the spectral methods and it is difficult to
in the simple case of a cantilever beam. The Zhao explain. However, the Dirlik method, although
and Baker method presented again great older than the others, demonstrated relatively small
discrepancies. errors, compared with the fatigue life in the time
Finally, Figure 6 illustrates the graph of fatigue life domain. As it is an empirical model that presents
errors relative to the time domain. peculiarities, this becomes clear, when it is applied
in complex structures.
Narrow Band Dirlik
It is emphasized that the transient simulation
Wirsching and Light Ortiz and Chen
implies in the solution of the equilibrium equations
hundreds or thousands of times for every second of
Benasciutti and Tovo Zhao and Baker
80
the total simulation time. Even with explicit
algorithms of complex structures modeled with
70
finer structural FE. This fact has required analyses
with hours or days of continuous simulation. Thus,
60
the optimization of these structures for objective
functions related to fatigue life has become
50 impractical, even for current computer hardware
technology. Therefore, the present study presents a
RELATIVE ERROR

40 contribution to the use of fatigue life analysis in the

frequency domain as a viable alternative to
30 engineering problems.

20 References

10
0
-10
CLASS
A 30
CLASS
A 60
CLASS
B 30
CLASS
B 60
KM/H KM/H KM/H KM/H
Figure 6: Relative error in cantilever beam with beam
elements.
The same behavior seen in the figure of the relative
error of a cantilever beam with plate elements is
observed with beam elements. The relative errors
are larger compared to the cantilever beam with
beam element. Finally, it is verified that the values
converge to 0 or fatigue life in the time domain.
Dynamic simulations with beam elements suggest
that the results are unreliable given the technology
and theory involved.
4. Conclusions
The results of fatigue life in the frequency domain
based on Dirlik model, are shown to be reliable for
the simple case of a cantilever beam, generating
coherent values. The greater advantage of the Dirlik
model is mainly minimize simulation time.
Simple cases are easy to solve in the time and
frequency domain, but the results serve only as a
baseline or preliminary studies.
Structural beam models presented significant
differences when compared to plate models. For the
simple case, cantilever beam, in road classes A and
B with speed of 30 km/h was observed exaggerated
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profiles - Reporting of measured data.
International Organization for Standardization,
Switzerland, 1995.
CLASS
C 30
CLASS
C 60
[2] Whler, A. Test to determine the forces acting
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[3] Goodman, J. Mechanics Applied to Engineering.
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[4] Miner, M. A. Cumulative damage in fatigue.
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[5] Rice, S. O. Mathematical Analysis of Random
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[6] Bendat, J. S. Probability Functions for Random
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Damage, and Catastrophic Failures. NASA
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[7] Wirsching, P. H.; Light, M. C. Fatigue Under
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[8] Chaudhury, G. K.; Dover, W. D. Fatigue
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[9] Ortiz, K.; Chen, N. K. Fatigue Damage [22] Higashida, Y.; Burk, J. D.; Lawrence, F. D. Jr.
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[12] Halfpenny, A. A Frequency Domain Approach
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[14] Benasciutti, D.; Tovo, R. Comparison of
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