Mechanical Add-ons Guide

ANSYS, Inc. Release 2024 R2

Southpointe July 2024
2600 Ansys Drive
Canonsburg, PA 15317 ANSYS, Inc. and
[email protected] ANSYS Europe,
Ltd. are UL
http://www.ansys.com registered ISO
(T) 724-746-3304 9001: 2015
(F) 724-514-9494 companies.
Copyright and Trademark Information

© 2024 ANSYS, Inc. Unauthorized use, distribution or duplication is prohibited.

ANSYS, Ansys Workbench, AUTODYN, CFX, FLUENT and any and all ANSYS, Inc. brand, product, service and feature
names, logos and slogans are registered trademarks or trademarks of ANSYS, Inc. or its subsidiaries located in the
United States or other countries. ICEM CFD is a trademark used by ANSYS, Inc. under license. CFX is a trademark
of Sony Corporation in Japan. All other brand, product, service and feature names or trademarks are the property
of their respective owners. FLEXlm and FLEXnet are trademarks of Flexera Software LLC.

Disclaimer Notice

THIS ANSYS SOFTWARE PRODUCT AND PROGRAM DOCUMENTATION INCLUDE TRADE SECRETS AND ARE CONFID-
ENTIAL AND PROPRIETARY PRODUCTS OF ANSYS, INC., ITS SUBSIDIARIES, OR LICENSORS. The software products
and documentation are furnished by ANSYS, Inc., its subsidiaries, or affiliates under a software license agreement
that contains provisions concerning non-disclosure, copying, length and nature of use, compliance with exporting
laws, warranties, disclaimers, limitations of liability, and remedies, and other provisions. The software products
and documentation may be used, disclosed, transferred, or copied only in accordance with the terms and conditions
of that software license agreement.

ANSYS, Inc. and ANSYS Europe, Ltd. are UL registered ISO 9001: 2015 companies.

U.S. Government Rights

For U.S. Government users, except as specifically granted by the ANSYS, Inc. software license agreement, the use,
duplication, or disclosure by the United States Government is subject to restrictions stated in the ANSYS, Inc.
software license agreement and FAR 12.212 (for non-DOD licenses).

Third-Party Software

See the legal information in the product help files for the complete Legal Notice for ANSYS proprietary software
and third-party software. If you are unable to access the Legal Notice, contact ANSYS, Inc.

Published in the U.S.A.

Table of Contents
Mechanical Add-ons ................................................................................................................................... xi
1. DesignLife Add-on .................................................................................................................................. 1
1.1. Make the DesignLife Add-on Available .............................................................................................. 1
1.2. The Ansys DesignLife Ribbon ............................................................................................................ 2
1.3. Using the DesignLife Add-on ............................................................................................................ 2
1.3.1. Choose the Analysis Domain .................................................................................................... 6
1.3.2. Choose the Analysis Type ......................................................................................................... 7
1.3.3. Analysis Settings ...................................................................................................................... 9
1.3.4. Create a Loading Event ........................................................................................................... 14
1.3.5. Specify Loads for Loading Events ............................................................................................ 15
1.3.5.1. Time Domain Loading Events ......................................................................................... 16
1.3.5.2. Frequency Domain Loading Events ................................................................................ 18
1.3.5.3. Comparison of Frequency Domain Add-On Results to Standalone DesignLife Results ...... 28
1.3.5.3.1. Single Frequency Loads ........................................................................................ 29
1.3.5.3.2. Frequency Range Loads ........................................................................................ 30
1.3.5.3.3. Consistent Acceleration Loading ........................................................................... 31
1.3.5.3.4. Vibration Generator Properties .............................................................................. 33
1.3.5.3.5. Vibration Load Provider ......................................................................................... 35
1.3.5.3.6. DesignLife SineDwell Using Vibration Generator .................................................... 37
1.3.5.3.7. DesignLife SineDwell Using DesignLife Properties ................................................. 39
1.3.5.3.8. DesignLife SineOnRandom Using Vibration Generator ........................................... 40
1.3.5.3.9. DesignLife SineOnRandom Using DesignLife Properties ......................................... 43
1.3.5.3.10. Vibration Generator to DesignLife for Frequency Range (Sine Sweep) ................... 43
1.3.6. Materials Assignment ............................................................................................................. 45
1.3.7. Solve ...................................................................................................................................... 52
1.3.8. Post-processing ...................................................................................................................... 53
1.3.8.1. Most Damaged Tabular Data and Series Output History .................................................. 54
1.3.8.2. Post-processing Static Failure ......................................................................................... 57
1.3.8.2.1. Post-Processing Static Failure for Damage and Life Results: .................................... 57
1.3.8.2.2. Damage Result - Maximum Damage Displayed ...................................................... 59
1.3.8.2.3. Life Result - Minimum Life Displayed ..................................................................... 60
1.3.8.3. Effect of Stress Averaging on Fatigue Results .................................................................. 62
1.3.8.4. Damage and Rainflow Matrix Plots ................................................................................. 66
1.3.8.5. Solid Seam Weld Life and Damage Vector Results ........................................................... 67
1.4. Performing the Solution .................................................................................................................. 67
1.4.1. Multi-threading ...................................................................................................................... 68
1.4.2. Local Solution ........................................................................................................................ 68
1.4.3. Ansys Remote Solve Manager (RSM) ....................................................................................... 68
1.4.4. HPC Platform Services (HPS) ................................................................................................... 68
1.4.5. Distributed Solve with MPI ..................................................................................................... 69
1.4.5.1. MPI Setup ...................................................................................................................... 69
1.4.5.2. DesignLife Addon MPI configuration .............................................................................. 70
1.5. Limitations ..................................................................................................................................... 72
2. NVH Toolkit Add-on .............................................................................................................................. 75
2.1. Make the NVH Add-on Available ...................................................................................................... 75
2.2. The NVH Ribbon ............................................................................................................................. 76
2.3. MAC Calculator ............................................................................................................................... 78
2.3.1. Adding a MAC Calculator result .............................................................................................. 78
2.3.2. MAC Calculator Details ........................................................................................................... 79

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. iii
Mechanical Add-ons Guide

2.3.2.1. File 2 Options ................................................................................................................ 79

2.3.2.2. MAC Calculation Options ............................................................................................... 82
2.3.2.3. Filtering Options ............................................................................................................ 84
2.3.2.4. Mode Pairing Options .................................................................................................... 84
2.3.2.5. Cyclic Optimization Options ........................................................................................... 85
2.3.2.6. Optimization Result ....................................................................................................... 86
2.3.3. MAC Calculation Method ........................................................................................................ 86
2.3.4. MAC Frequency Worksheet ..................................................................................................... 87
2.3.5. UNV Node Worksheet ............................................................................................................. 89
2.3.6. MAC Calculator Generation .................................................................................................... 90
2.3.7. 2D MAC Table ......................................................................................................................... 90
2.3.8. 3D MAC Table ......................................................................................................................... 92
2.3.9. COMAC Table ......................................................................................................................... 93
2.3.10. Coordinate Modal Assurance Criterion Calculation ................................................................ 94
2.3.11. Complex to Real Projection Methodology ............................................................................. 94
2.3.12. Automatic Mode Pairing Algorithm ....................................................................................... 95
2.3.13. Objective Function Formulation ........................................................................................... 96
2.3.14. Modal Phase Collinearity ...................................................................................................... 96
2.3.15. Mode Animation View .......................................................................................................... 97
2.3.16. MAC Table export ................................................................................................................. 98
2.4. Stress/Strain Recovery ..................................................................................................................... 99
2.4.1. Adding a Stress/Strain recovery result ..................................................................................... 99
2.4.2. Stress/Strain Recovery Details ............................................................................................... 100
2.4.3. MCF Restrictions .................................................................................................................. 102
2.5. FRF Calculator ............................................................................................................................... 102
2.5.1. Adding an FRF Calculator Result ........................................................................................... 103
2.5.2. FRF Calculator Details ........................................................................................................... 104
2.5.3. FRF Calculation Method ........................................................................................................ 107
2.5.4. FRF Worksheet ..................................................................................................................... 108
2.5.5. FRF Plotter ........................................................................................................................... 112
2.5.6. FRF Comparison Plotter ........................................................................................................ 114
2.6. Pre-Test Calculator ........................................................................................................................ 117
2.6.1. Adding a Pre-Test Calculator Result ....................................................................................... 117
2.6.2. Pre-Test Calculator Details .................................................................................................... 118
2.6.3. Sensor Identification Method ............................................................................................... 120
2.6.4. Sensors AutoMAC Panel ....................................................................................................... 122
2.6.5. Exciter Identification Method ................................................................................................ 123
2.6.6. Pre-Test Worksheet ............................................................................................................... 124
2.6.7. Sensor Mass Effect Analysis ................................................................................................... 127
2.6.8. Automatic Coordinate System Definition .............................................................................. 127
2.7. EM Loads - XML Converter ............................................................................................................. 128
2.7.1. Launching the XML Converter Wizard ................................................................................... 128
2.7.2. Using the XML Converter Wizard ........................................................................................... 128
2.7.3. Closing the XML Converter Wizard ........................................................................................ 129
2.8. UNV File Restrictions ..................................................................................................................... 129
3. Forced Response Add-on .................................................................................................................... 133
3.1. Introduction to Forced Response ................................................................................................... 133
3.2. Make the Forced Response Add-on Available ................................................................................. 136
3.3. Setting Up the Forced Response Analysis ....................................................................................... 136
3.3.1. Setting Up the Static Structural Analysis ................................................................................ 137
3.3.2. Setting Up the Modal Analysis .............................................................................................. 137

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
iv of ANSYS, Inc. and its subsidiaries and affiliates.
 Mechanical Add-ons Guide

3.3.3. Setting Up the Harmonic Analysis ......................................................................................... 138

3.3.4. Setting Up the Interference Diagram .................................................................................... 140
3.3.5. Mistuning Settings ............................................................................................................... 141
3.3.6. AeroCoupling Settings ......................................................................................................... 144
3.4. Multistage Harmonic Choice Wizard .............................................................................................. 145
3.5. Multiharmonic Combination ......................................................................................................... 151
3.5.1. Multiharmonic Plot (DPF) ...................................................................................................... 152
3.5.2. Multiharmonic Chart ............................................................................................................ 154
3.6. Post-processing ............................................................................................................................ 156
3.6.1. Mode Multiplier ................................................................................................................... 156
3.6.2. Export Results ...................................................................................................................... 157
3.6.3. Fatigue Diagram ................................................................................................................... 157
3.6.4. Matrices ............................................................................................................................... 159
3.6.5. Optimize Blade Sequences ................................................................................................... 160
3.7. Troubleshooting ........................................................................................................................... 160
4. Explicit Dynamics Add-ons ................................................................................................................. 161
4.1. Drop Test Add-on .......................................................................................................................... 161
4.2. The LS-DYNA Keyword Manager Add-on ........................................................................................ 161
5. Bolt Tools Add-on ................................................................................................................................ 163
5.1. Making the Bolt Tools Add-on Available ......................................................................................... 163
5.2. Bolt Tools Add-on Definitions ........................................................................................................ 163
5.2.1. Bolt Geometry Auto-Recognition .......................................................................................... 164
5.2.2. Object Summary Tables ........................................................................................................ 165
5.3. Bolt Tools Modeling Buttons .......................................................................................................... 165
5.3.1. Selection .............................................................................................................................. 165
5.3.2. Contact ................................................................................................................................ 167
5.3.3. Meshing ............................................................................................................................... 169
5.3.4. Coordinate Systems .............................................................................................................. 169
5.3.5. Preloads ............................................................................................................................... 171
5.3.6. Beams .................................................................................................................................. 172
5.3.7. Post Processing .................................................................................................................... 172
5.3.8.Tree Helper ........................................................................................................................... 173
5.4. Bolt Tools Modeling Wizard ........................................................................................................... 174
5.4.1. Common and Reused Wizard Tabs ........................................................................................ 174
5.4.2. Wizard Interfaces .................................................................................................................. 177
5.4.2.1. Setup Wizard ............................................................................................................... 178
5.4.2.2. Surface Body Hole Detection Wizard ............................................................................ 187
5.4.2.3. Cone of Compression Imprint Wizard ........................................................................... 188
5.4.2.4. Reactions Probe Wizard ............................................................................................... 190
5.4.2.5. Connections Post Wizard ............................................................................................. 190
5.4.2.6. Contact Results Wizard ................................................................................................ 192
5.5. Bolt Tools Instance Manager .......................................................................................................... 193
5.5.1. Instance Manager Properties ............................................................................................... 193
5.5.2. Instance Manager Geometry Selection .................................................................................. 194
5.5.3. Instance Groups ................................................................................................................... 194
5.5.4. Instance Group Properties ................................................................................................... 195
5.5.5. Geometry Selection .............................................................................................................. 196
5.6. Instances - Part Library .................................................................................................................. 197
5.6.1. Part Library Interface ........................................................................................................... 197
5.6.2. Adding a Part to the Library .................................................................................................. 198
5.6.3. Referencing and Using a Part from the library ....................................................................... 198

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. v
Mechanical Add-ons Guide

5.6.4. Part File Structure and Format .............................................................................................. 199

5.6.5. Part Auto-Recognition and Matching Criteria ....................................................................... 200
5.6.6. Part Script Files ..................................................................................................................... 200
5.7. APDL Bolt Modeling ...................................................................................................................... 201
5.7.1. APDL Bolt Mechanical Tree Object ........................................................................................ 201
5.7.2. APDL Bolt Part Files ............................................................................................................. 201
5.7.3. APDL Bolt Properties ............................................................................................................ 203
6. optiSLang 3D Postprocessing Add-on ................................................................................................ 205
7. Restart Analysis Add-on ...................................................................................................................... 207
8. Hydrodynamic Add-ons ...................................................................................................................... 215
8.1. Hydrodynamic Pressure ................................................................................................................ 215
8.2. Offshore ....................................................................................................................................... 215
8.3. Aqwa Co-simulation ...................................................................................................................... 215
9. Additive Manufacturing Add-ons ....................................................................................................... 217
9.1. LPBF Process ................................................................................................................................. 217
9.2. DED Process .................................................................................................................................. 217
9.3. Sintering Process .......................................................................................................................... 217
9.4. Distortion Compensation .............................................................................................................. 217
10. Rigid Dynamics Add-ons ................................................................................................................... 219
10.1. Variable Load .............................................................................................................................. 219
10.2. Motion Load Transfer .................................................................................................................. 219
11. Add-ons Tutorials .............................................................................................................................. 221

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
vi of ANSYS, Inc. and its subsidiaries and affiliates.
List of Figures
1.1. Active DesignLife Icon on the Add-ons Ribbon ........................................................................................ 1
1.2. Ansys DesignLife Ribbon ......................................................................................................................... 2
1.3. Modify Material Parameters ................................................................................................................... 46
1.4. Materials Properties for Strain Analysis .................................................................................................. 47
1.5. Materials Properties for Stress Analysis .................................................................................................. 49
1.6. Most Damaged tabular data .................................................................................................................. 54
1.7. Series Output History: Time domain case ............................................................................................... 55
1.8. Series Output History: Frequency domain case ...................................................................................... 55
1.9. Selecting a specific Time Series Output .................................................................................................. 56
1.10. Series Output History: Single output display ........................................................................................ 56
1.11. Series Output History: Extracting peak information .............................................................................. 56
1.12. Series Output History: Minimum and maximum values ........................................................................ 57
1.13. Example of Life result where the purple band corresponds to the Static Failure .................................... 58
1.14. Example of Damage s where the purple band corresponds to the Static Failure .................................... 58
1.15. Calculated damage in some areas is above the specified maximum damage ........................................ 59
1.16. Maximum Damage display limit not reached ....................................................................................... 60
1.17. Calculated life in some areas is below the specified minimum life ......................................................... 61
1.18. Minimum Life display limit not reached ............................................................................................... 61
1.19. Hex mesh - Mechanical Fatigue Tool - Top Face Life .............................................................................. 62
1.20. Hex mesh - Mechanical Fatigue Tool - Top Face Equivalent Alternating Stress ........................................ 63
1.21. Hex mesh - DesignLife Add-on - Top Face Life ...................................................................................... 63
1.22. Hex mesh - DesignLife Add-on - Top Face Equivalent Alternating Stress ................................................ 63
1.23. Hex mesh - DesignLife Standalone - Top Face Life ................................................................................ 63
1.24. Hex mesh - DesignLife Standalone - Top Face Equivalent Alternating Stress .......................................... 64
1.25. Tet mesh - Mechanical Fatigue Tool - Top Face Life ............................................................................... 64
1.26. Tet mesh - Mechanical Fatigue Tool - Top Face Equivalent Alternating Stress ......................................... 64
1.27. Tet mesh - DesignLife Add-on - Top Face Life ........................................................................................ 64
1.28. Tet mesh - DesignLife Add-on - Top Face Equivalent Alternating Stress ................................................. 65
1.29. Tet mesh - DesignLife Standalone - Top Face Life .................................................................................. 65
1.30. Tet mesh - DesignLife Standalone - Top Face Equivalent Alternating Stress ........................................... 65
1.31. Damage Matrix ................................................................................................................................... 67
1.32. MPI configuration for DesignLife ......................................................................................................... 71
2.1. Active NVH Icon on the Add-ons Ribbon ................................................................................................ 75
3.1. Active Forced Response Icon on the Add-ons Ribbon ........................................................................... 136
3.2. Interference Diagram with Three Speed Lines ...................................................................................... 141
3.3. Calculate Indices Dialog in Multistage Harmonic Choice Wizard ........................................................... 146
3.4. Nodal Diameter Calculations for Stage 1 .............................................................................................. 148
3.5. Nodal Diameter Calculations for Stage 2 .............................................................................................. 148
3.6. Harmonic Index Calculations ............................................................................................................... 149
3.7. Nodal Diameter Calculations for Stage 1 .............................................................................................. 149
3.8. Nodal Diameter Calculations for Stage 2 .............................................................................................. 150
3.9. Harmonic Index Calculations ............................................................................................................... 150
3.10. Harmonic Index Calculations for All Nodal Diameters ......................................................................... 151
4.1. Drop Test Add-on Showing Loaded Status ........................................................................................... 161
5.1. Active Bolt Tools Icon on the Add-ons Ribbon ...................................................................................... 163
5.2. Bolt Tools Ribbon ................................................................................................................................ 163
5.3. Basic Bolt Terms .................................................................................................................................. 164
5.4. Bolt Thread Partitioning ...................................................................................................................... 164
5.5. Bolt Tools Modeling Buttons ................................................................................................................ 165

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. vii
Mechanical Add-ons Guide

5.6. Bolt Tools Selection Tools .................................................................................................................... 166

5.7. Bolt Tools Contacts Tools ..................................................................................................................... 168
5.8. Bolts Body Coordinate Systems Conventions ....................................................................................... 170
5.9. Coordinate Systems Options and Actions ............................................................................................ 170
5.10. Beams Options and Actions ............................................................................................................... 172
5.11. Post Processing Options and Actions ................................................................................................. 173
5.12. Tree Helper Options and Actions ....................................................................................................... 173
5.13. Bolt Tools Wizards Button .................................................................................................................. 174
5.14. Reaction Probes Create Tab ............................................................................................................... 176
5.15. Contacts under Reaction Probes Create Tab ....................................................................................... 176
5.16. Reaction Probes Reporting Tab .......................................................................................................... 177
5.17. Bolt Tools Wizards Menu .................................................................................................................... 178
5.18. Coordinate Systems Tab .................................................................................................................... 179
5.19. Mesh Tab .......................................................................................................................................... 181
5.20. Named Selections Tab ....................................................................................................................... 183
5.21. Pretension Tab .................................................................................................................................. 184
5.22. Contacts Tab ..................................................................................................................................... 187
5.23. Hole Detection Tab ............................................................................................................................ 188
5.24. Cone of Compression Imprint Wizard ................................................................................................. 189
5.25. APDL Info Tab ................................................................................................................................... 190
5.26. Beams Tab ........................................................................................................................................ 191
5.27. Joints Tab .......................................................................................................................................... 191
5.28. Create Contact Results Tab ................................................................................................................ 192
5.29. Image Export Options Tab ................................................................................................................. 192
5.30. Report Generation Tab ...................................................................................................................... 193
5.31. Bolt Tools Instances Button ................................................................................................................ 193
5.32. Instances Options and Actions .......................................................................................................... 196
5.33. Accessing the Parts Library ................................................................................................................ 197
5.34. Part Library Window .......................................................................................................................... 198
5.35. Referencing and Using a Part from the Library ................................................................................... 199

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
viii of ANSYS, Inc. and its subsidiaries and affiliates.
List of Tables
3.1. Allowed results for each selection type ................................................................................................ 156

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. ix
 Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
x of ANSYS, Inc. and its subsidiaries and affiliates.
Mechanical Add-ons
The Add-ons Ribbon includes a curated selection of Ansys-provided Mechanical Add-ons, formerly referred
to as ACT extensions. This easy access eliminates the need to open the Extensions Manager. Add-ons
are grouped into related functional areas such as hydrodynamic loads, additive manufacturing, rigid
dynamics, and so on.

Loading and Unloading Add-ons

To load an add-on, simply click the desired icon in the Add-ons Ribbon. Once an add-on is loaded, its
icon in the ribbon will be highlighted in blue and a new tab is added. To unload an add-on, simply click
the icon in the ribbon again. The tab goes away.

The loaded/unloaded status of an add-on is persistent (stored in the application's appdata), meaning
an add-on will keep that status the next time you open Mechanical. You may want to unload an add-
on after each use.

It is important to note that Workbench must be free when loading or unloading add-ons, so ensure the
Extensions Manager is closed in Workbench before using the Add-ons Ribbon.

Finding Help for an Add-on

To access the documentation for any add-on, hover over the icon of the desired add-on. Once the
tooltip is displayed, press the F1 key. It will open the corresponding documentation for the selected
add-on. If you want to review all functions of the add-ons, click the Add-ons Help entry in the Support
group of the Add-ons Ribbon.

Known Limitations
• The DesignLife, Forced Response, and Restart Analysis Add-ons support English, Chinese, Japanese,
French, and German languages (including associated decimal separators). All other Mechanical Add-
ons support English only.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. xi
Mechanical Add-ons

• When you open Mechanical independently in combination with using any of the Mechanical Add-
ons, the following sequence may produce an undesirable issue:

1. Open Mechanical independently (without Workbench)

2. Load any Mechanical Add-on

3. Use the add-on to add a custom object to the project tree

4. Save the project

5. Click File > New to open a new project

At this point, you would expect the project to have been cleared, but the Mechanical application
acts as if there is already an add-on-specific object in the tree. This is the defect. For example, attempt-
ing to unload the add-on results in the following warning message: “Add-on cannot be unloaded because
there are objects created with it in the Project,” despite the fact that there are no objects in the tree.
Furthermore, if the add-on you initially used allows only one instance of an item in the tree, this defect
prohibits you from adding a new instance of that object since it believes one already exists.

Workaround: Close Mechanical and directly open (double click) your saved project. Avoid the "File >
New" operation when opening Mechanical independently in combination with any of the Mechanical
Add-ons.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
xii of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 1: DesignLife Add-on
The Mechanical Embedded DesignLife UI is an add-on to the Ansys Mechanical User Interface that
makes the fatigue analysis capabilities of the nCode DesignLife product available from within the
Mechanical environment. The nCode DesignLife product is a partner product from HBM Prenscia.

The DesignLife Add-on is developed to evaluate fatigue life. Using the results of finite element analysis
(FEA) from Ansys Mechanical and Ansys LS-DYNA, it accumulates damage from repetitive loading to
determine a product's predicted life. You can quickly evaluate the effects of different materials and al-
ternative geometries for new designs and optimize design variables for the product's expected usage
before exhaustive and expensive prototyping and testing.

The DesignLife UI Add-on is only available on the Windows operating system. Its use also requires an
Ansys nCode DesignLife license. If you do not already have the license, contact your Ansys Sales Rep-
resentative to obtain one.

For more information about fatigue analysis in Ansys Mechanical, see Fatigue Results.
1.1. Make the DesignLife Add-on Available
1.2.The Ansys DesignLife Ribbon
1.3. Using the DesignLife Add-on
1.4. Performing the Solution
1.5. Limitations

1.1. Make the DesignLife Add-on Available

To make the DesignLife capabilities available, click the DesignLife Icon in the Add-ons ribbon. The icon
will be highlighted in blue, indicating that the add-on is loaded.

Figure 1.1: Active DesignLife Icon on the Add-ons Ribbon

Once the add-on is loaded, the Ansys nCode DesignLife Ribbon is visible.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 1
DesignLife Add-on

1.2. The Ansys DesignLife Ribbon

When the DesignLife Add-on is loaded, the Ansys DesignLife ribbon is accessible. Insert a DesignLife
analysis from within Mechanical by clicking on the DesignLife Analysis icon.

Figure 1.2: Ansys DesignLife Ribbon

1.3. Using the DesignLife Add-on

DesignLife analysis options are available in Workbench as follows:
1.3.1. Choose the Analysis Domain
1.3.2. Choose the Analysis Type
1.3.3. Analysis Settings
1.3.4. Create a Loading Event
1.3.5. Specify Loads for Loading Events
1.3.6. Materials Assignment
1.3.7. Solve
1.3.8. Post-processing

After the DesignLife Add-on is loaded, a Mechanical Embedded DesignLife system appears in the
Toolbox:

As an alternative method of inserting an DesignLife Analysis, you can drag and drop this system onto
the Model cell of any existing system:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
2 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

To perform Design Points Studies, the Solution cell of the loading system must be connected to the
Setup cell of the Mechanical Embedded DesignLife system. If the Solution cell is not connected, you
need to include at least one value of the loading system as an output parameter so that the new
loading system results are calculated and accounted for in the Mechanical Embedded DesignLife
parameter study.

To get detailed Help on the calculations that DesignLife performs, open the DesignLife tab in Mechan-
ical and click the Help button:

Compatible Upstream Systems

Static, Transient, WB LS-DYNA, Sherlock, Modal or Harmonic systems can be used as upstream systems
for performing fatigue calculations using the Mechanical Embedded DesignLife system.

• Static, Transient and WB LS-DYNA can be directly connected to a DesignLife analysis to perform
fatigue calculations.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 3
DesignLife Add-on

• Modal and Harmonic systems can be connected to a DesignLife analysis to perform vibration
fatigue calculations. To include static offset, additional upstream systems can be connected. To
perform a vibration fatigue calculation, select the frequency-based time domain (p. 6) analysis
and insert frequency-based loading conditions (p. 18).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
4 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

• To perform PCB fatigue analysis calculations, Sherlock data can also be connected as an upstream
system. Sherlock data can be consumed either by connecting the Sherlock (Pre) system or im-
porting the Sherlock information via the Mechanical model (see below).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 5
DesignLife Add-on

1.3.1. Choose the Analysis Domain

Under Analysis Settings > Analysis Domain, choose an analysis domain. Choose betweeen Time
based and Frequency based.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
6 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Default setting: If a Harmonic system is linked with the nCode DesignLife Add-on system, the Analysis
Domain defaults to Frequency based. Otherwise, Time based is the default.

1.3.2. Choose the Analysis Type

1. Under Analysis Settings > Analysis Type, since there is no default setting, you must choose
one of the analysis types: Strain Life, Stress Life, Shell Seam Weld, Solid
Seam Weld, Spot Weld or Gray Iron.

• Select Strain Life to perform the nCode Standard EN Analysis Engine.

• Select Stress Life to perform the nCode Standard SN Analysis Engine.

• Select Shell Seam Weld to perform the nCode SeamWeld Analysis Engine on
shells.

• Select Solid Seam Weld to perform the nCode SeamWeld Analysis Engine on
solids.

Note:

The Shell Seam Weld and Solid Seam Weld analysis types require an Ansys
nCode DesignLife Enterprise license.

• Select Spot Weld to perform the nCode SpotWeld Analysis Engine.

Note:

The Shell Seam Weld and Spot Weld analysis types require that the up-
stream systems be solved with the Output > Nodal Forces Analysis Settings
set to Yes.

• Select Gray Iron to perform the nCode GrayIron EN Analysis Engine. To perform
Gray Iron analysis, ensure that Gray Iron Material Properties (p. 52) are defined.

• Select Safety Factor Analysis to perform the nCode Safety Factor Analysis
Engine. There are several combination methods used to calculate stress-based safety
factors. This implementation employs a method used in both the rail and road vehicle

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 7
DesignLife Add-on

industries where the stress is resolved to the plane of the maximum absolute principal
stress (MaxPrincipalPlane), along with standard stress combination methods such as
AbsMaxPrincipal and CriticalPlane. The available materials are MultiMean and
MultiRRatio curves.

• Select Short Fiber Composite Analysis to perform the nCode Short Fiber
Composite Analysis Engine. This analysis engine performs an SN-based analysis using
short fiber, orientation-dependent materials.

The method used to define the SN curves used by the fatigue calculation (SNMethod)
for Short Fiber Composite Analysis is the Basquin method. This method uses a set of
one or more parameterized stress-life curves, and interpolates between them (or ex-
trapolates) based on the share of fibers in the direction of the loading. Each individual
SN curve is similar to the standard SN formulation.

The local SN curve will be determined based on a set of SN (Basquin) curves from the
nCode MXD database. The corresponding Material Type property for the material
map should be set to Short Fiber Composite Basquin Curves. The dataset used for
Short Fiber Composite Analysis is the nCodeSFCBasquinCurveContainer.

The only supported Solution Location for Composite Analysis is Element. Results will
be recovered from the element centroid. If element centroid results are not available
in the FE results file, nCodeDT will average the stresses from the nodes.

The EntityDataType nCode property is set to Stress. Therefore, stresses will be re-
covered from the FE results file. Stresses can result from a static, transient, or modal
analysis, but will normally be from an elastic analysis.

2. Once you have selected the analysis type, Solution Group and Load Mapper options are
exposed.

3. Under Solution Group, select the portion of the model to be analyzed. By default, the entire
model is used. Only flexible bodies are supported for a fatigue analysis. If rigid bodies are
scoped as part of the solution group, they will be automatically excluded.

Note:

For Shell Seam Weld, Solid Seam Weld and Spot Weld cases, ensure that the
Solution Group is scoped only to the welds.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
8 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

1.3.3. Analysis Settings

Under Analysis Settings, set the desired values for:

• Mean Stress Correction (default = None).

• Multiaxial Assessment (default = Auto). Multiaxial Assessment provides information about

how the stress state varies throughout the loading history. There are three assessment options:

– None - If None is selected, no multiaxial assessment results are produced and the
Combination Method setting is exposed (see below).

– Standard - This method is a more recent development that provides a more robust
measure of the biaxiality and non-proportionality of the local loading (stress state).

– Auto - Auto mode uses a two-pass approach, which overrides the Combination
Method setting. The Auto option is not compatible with Short Fiber Composite ana-
lysis.

• Combination Method (default = Abs Max Principal). The analysis engine uses the information
from the load provider to create a stress tensor history σij(t). In order to make a fatigue calcu-
lation, you need to reduce this stress tensor to a scalar value so that you can cycle-count it
and compare the resulting cycles to the local S-N curve. This process is called stress combination.
The available options for combined stress parameters are as follows:

– Abs Max Principal - The Absolute Maximum Principal stress is defined as the principal
stress with the largest magnitude.

– Signed vonMises - The Signed von Mises stress is the von Mises stress, but forced to
take the sign of the Absolute Maximum Principal stress. Short Fiber Composite and
Solid Seam Weld analysis do not support this method.

– Critical Plane - The normal stress is calculated and rainflow is counted on multiple
planes. The critical plane is the plane with the highest predicted fatigue damage. For
stresses flagged as 2D, the planes on which the normal stress is determined have normals
that lie in the plane of the physical surface (in the x-y plane of the 2D stress results
coordinate system). The orientation of each plane is defined by the angle f made with
the local x-axis.

• Elastic-Plastic Correction. If the Analysis Type is set to Strain Life, the Elastic-plastic
Correction option is exposed. Choose between Neuber, Hoffmann-Seeger, or None options.
The None option should be used when plastic stress or strain are present.

Note:

The None option is only available for Ansys Mechanical Premium or Ansys Mechan-
ical Enterprise license.

For Stress Life analysis, if the .rst files used for loading contain plastic results, check the
results carefully. The add-on notifies you by issuing the warning message: "FE contain plastic
stress/strain results, which are invalid for SN fatigue. Check results carefully."

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 9
DesignLife Add-on

For Strain Life analysis, if the .rst files used for loading contain plastic results, use the None
option or check results carefully. The add-on notifies you by issuing the warning message: "FE
contain plastic stress/strain results. Set the Elastic-Plastic correction to None for accurate results.
This option is not available with PRO license. Check results carefully."

Note:

For the Strain Life Analysis Type, if MultiAxial Assessment is set to Auto, then
the Elastic-plastic Correction used by the nCode solver will be Hoffmann-Seeger,
regardless of any manual setting. A different Elastic-plastic Correction method for
this scenario would only be considered for the Safety Factor calculation.

• Large Displacements (default = No). If an FE model has been solved with large displacements
then this must be taken into account when performing stress transformations such as when
resolving the stress to the surface or calculation of averaged nodal stresses. This option should
be set to Yes when large displacements are present, and in order to use this option the
model displacements must be included in the FE results. The default value for this option is
No and this option should only be used when necessary because it will result in a slower
analysis. The Large Displacements option is not supported for the Solid Seam Weld Analysis
Type.

• Stress Gradients (default = Off ). This property has two possible values:

– Off - no stress gradient correction is applied.

– Auto - a correction for stress gradients is applied if stress gradients are present.

When the Auto option is set, the Stress Gradient Method option is displayed. This property
has two possible values:

– VonMises (default) - Stress gradient corrections are based on a scalar measure of stress
(see Stress Gradients above).

– AbsMaxPrincipal - The stress gradient calculation can also be based on the absolute
maximum principal stress. In this case, the gradient of the AbsMaxPrincipal stress is
determined in the surface normal direction and this is normalised with respect to the
AbsMaxPrincipal stress at the surface.

To visualize the stress gradient factors, insert an Other Results result object under the Solution
and set the Result Type to Stress Gradient Factors. Note that the nCode Material Type
must be defined through materials assignment, or the nCode solver will generate the following
error message when trying to solve:

Material type not supported for auto stress gradient correction :

0

• Solution Location (default = AveragedNodeOnElement). This option can only be changed

for Stress Life and Safety Factor analysis types. If Solution Location is set to WeldHotSpot,
the nCode solver will look for stress results from solid elements. The stress tensor at the weld
toe will be obtained by extrapolation of the surface stress from 2 or 3 points near to the weld.

When Solution Location is set to WeldHotSpot, some additional properties need to be set:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
10 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

– Offset Type: Defines whether the hotspot stress extrapolation is dependent on the
plate thickness. Set this to Ratio to calculate the offset based on weld thickness. Set it
to Distance to offset points by a fixed distance in mm.

– Extrapolation Points: Whether to use linear (two-point) or quadratic (three-point) ex-

trapolation.

– Maximum Weld Depth: The maximum weld depth in the units of the .rst file (length).
Only visible when the Offset Type (above) is set to Ratio.

– Mesh Quality: Whether to use linear (two-point) or quadratic (three-point) extrapolation.

Only visible when Offset Type is set to Ratio and only considered when Extrapolation
Points is set to Two.

– Offset Method: Defines which method to use to specify the offset values used in the
hot spot stress calculation. Set this to Default to use software-defined distances and
ratios. Set it to Custom to specify a user-defined, comma-separated list of distances or
ratios.

– Offset Values: Comma separated list of two or three distances (mm) or ratios. Only
valid when Offset Method is set to Custom.

– Weld Definition File Name: The name of the weld definition .xml file. When the Weld
Definition File Name is loaded, the number of weld lines is detected and these are
populated in the tabular data so that they can be mapped to the corresponding mater-
ial.

• Maximum Weld Depth. This option sets the maximum depth to go into the model when de-
fining the results locations within solid elements. It is therefore only available for the Solid
Seam Weld analysis type. If the value is set to zero, the maximum depth will be the total
thickness at each weld location. Any value entered must be > 0.

• Scale Factor (default = 1).

• Calculate Safety Factor (default = No). This option sets the back calculation method. This
safety analysis method corresponds to the Scale Factor back calculation mode in DesignLife
and should not be confused with the stress-based factor of the safety analysis engine.

This method corresponds to the Strain Life glyph's back calculation capabilities to assess how
the stress should be increased or decreased to meet the target life. This is called a back calcu-
lation because you know the fatigue life and want to calculate the stress level, which would
normally be an input parameter. This type of back calculation provides quantifiable stress or
strain reduction targets for redesign or countermeasures.

The back calculation method is also possible with a Duty Cycle (see Create a Loading
Event (p. 14)) as follows:

– If EventProcessing is set to Independent, then back calculation is done separately for

each event.

– Then, if OutputEventResults is set to True, a scale factor is reported for each event.
The scale factor result for the whole duty cycle is taken to be the lowest scale factor
from any event.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 11
DesignLife Add-on

– If EventProcessing is set to one of the combination methods, then back calculation is

done over the whole duty cycle.

Note:

If Calculate Safety Factor is set to Yes and there is a duty cycle, the Combination
Method cannot be set to Critical Plane.

• Certainty of Survival (default = 50.0). The certainty of survival is a real number that specifies
the certainty of survival based on material data scatter. The certainty of survival (in %) allows
statistical variations in material behavior to be taken into account. As mentioned in the nCode
DesignLife guide, the usual application of this is to provide a more conservative prediction to
ensure a safer design. The variability in material properties is characterized by standard error
parameters, which should be determined when fitting material curves to Strain-Life and Cyclic
Stress-Strain test data. The certainty of survival values are converted into a number of standard
errors using the lookup table and this is used to adjust the cyclic stress-strain and strain-life
curves, as described previously.

This value must be >= 0.00003 and <= 99.99997.

• Safety Factor Analysis Settings:

– Factor of Safety Type. This property is specific to the Safety Factor analysis type.

For Haigh curves, the safety factor can be calculated based on a constant R ratio or a
constant mean stress. The calculation of the safety factor is based on the distance of
the mean stress/stress amplitude from the Haigh constant life line.

The available options are as follows:

→ ConstantMean - The distance is calculated by starting from the zero stress

amplitude axis and going vertically through the point to intersect the line,
keeping the same mean stress.

→ ConstantRRatio - A line is drawn from the origin through the stress point and
extended until it intersects the Haigh curve.

→ ConstantMinimum - The distance is calculated by starting from the zero stress

amplitude point and going vertically through the point to intersect the line,
keeping the same minimum stress on a plot of maximum vs. minimum cycle
stress.

→ ConstantMaximum - The distance is calculated by starting from the zero stress

amplitude point and going vertically through the point to intersect the line,
keeping the same maximum stress on a plot of minimum vs. maximum cycle
stress.

– Target Life. This property is specific to the Safety Factor analysis type. This is the target
life that is used to calculate the allowed stress value used in the safety factor calculation.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
12 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

When Haigh curves are used, the Target Life is used to interpolate a single curve for
the required life. If a single Haigh curve is selected and the life does not match the
Target Life, this will cause an error.

– Max Safety Factor. This property is specific to the Safety Factor analysis type. This is
an adjustment to improve the plot.

• Short Fiber Composite Analysis:

– Orientation Tensor File: Specifies an ASCII/XML file containing material orientation

tensors.

Composites, in general, have anisotropic structures and properties. The material orient-
ation tensor describes the microstructure in terms of the distribution of fiber orientations
at each calculation point (element, layer, section point) in the structure, and this inform-
ation is required if nCodeDT is to take into account the anisotropy of fatigue properties
in the analysis. The material orientation tensor will normally be derived from a simulation
of the manufacturing process. The nCode MaterialOrientationTensor property is set
to ASCIIFile and the file specified by Orientation Tensor File must be in this Glyph-
works-compatible CSV format:
#HEADER
#CHANTITLE
Orientation Tensors
#TITLES
Element,Layer Number,Section Point,a11,a22,a33,a12,a23,a13
#KEYWORDS
ElementID,LayerNumber,Section Point,a11,a22,a33,a12,a23,a13
#DATATYPES
LONG,LONG,LONG,FLOAT,FLOAT,FLOAT,FLOAT,FLOAT,FLOAT
#DATA
1,1,1,0.9483,0.04747,0.004257,-0.003031,2.619E-5,-0.005304
1,2,1,0.7847,0.209,0.006283,-0.002284,-3.154E-5,-0.003902
1,3,1,0.5095,0.4853,0.005148,-7.342E-4,-2.02E-5,-0.003999
1,4,1,0.2087,0.7901,0.001193,0.007548,2.444E-5,-0.002749

Columns with these keywords and types must be present:

→ ElementID (Element ID) - long or huge

→ LayerNumber (Layer Number≥1) - long or huge

→ Section Point (Section Point≥1) - long or huge

→ a11 - (orientation tensor component) float or double

→ a22 - (orientation tensor component) float or double

→ a33 - (orientation tensor component) float or double

→ a12 - (orientation tensor component) float or double

→ a23 - (orientation tensor component) float or double

→ a13 - (orientation tensor component) float or double

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 13
DesignLife Add-on

Metadata can optionally be used to set a default orientation tensor. This is used for any
locations not present in the data section of the file. If required, it must be placed in the
header with this format:
#TESTMETADATA
"OrientationTensor.Default,1,0,0,0,0,0"

This specifies a property set named OrientationTensor with a string property named
Default. The tensor must be specified as a comma-separated list of six numeric values.

• Solve Process Settings:

– Number of Analysis Threads (default = 4): More than four threads requires an Ansys
nCode DesignLife Parallel Add-on license.

The Number of Analysis Threads property can be used to set the number of threads
for a job or an individual run. For a distributed job, this count will apply to each process
that comprises the job. This property corresponds to the NumAnalysisThreads para-
meter in the input.dcl file consumed by the nCode solver.

– Number of Translational Processes (default = 2): This property controls the number
of processes used simultaneously during the translation process. It corresponds to the
NumTranslationProcesses parameter in the input.dcl file consumed by the nCode
solver.

– Use MPI (default = No): When set to Yes, this enables distributed solution through MPI.
See Distributed Solve with MPI (p. 69) for more information.

– MPI nodes. The total number of nodes to use for MPI (see above).

– Host 2. The name of the second host for the MPI distributed solution (see above).

1.3.4. Create a Loading Event

You can create any number of Loading Events in the following ways:

• Click Add in the Details Window of Load Mapper :

• Alternatively, you can right-click Load Mapper and choose Add Loading Event:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
14 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Multiple Loading Events create a duty cycle:

This exposes the Combination Method parameter (default = Fast):

Loading Events in the Time based Analysis Domain can include multiple loadings of the same type.
Loading Events in the Frequency based Analysis Domain can only support one loading case per
loading event.

A Loading Event can be imported and exported using a .csv file.

Additional loads and properties are frequently added with each new software release, so you must
ensure that an imported .csv is compatible with the current version. In case of doubt, you can check
the current .csv format by exporting loading events before importing.

When importing .csv loading events, the environment system must exist and the selected time step
must be contained in the corresponding result file. If the selected time step does not exist, the loading
event will not be successfully defined, and the loads will activate automatically when selecting the
loading event. If this happens, redefine the time to a step that does exist in the results file.

1.3.5. Specify Loads for Loading Events

Loads can be specified for loading events in both the Time-based and Frequency-based Analysis
Domain.
1.3.5.1.Time Domain Loading Events
1.3.5.2. Frequency Domain Loading Events
1.3.5.3. Comparison of Frequency Domain Add-On Results to Standalone DesignLife Results

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 15
DesignLife Add-on

1.3.5.1. Time Domain Loading Events

To specify loads for Time Domain Loading Events:

• Click Add Load under Loading Event to add a load (Constant Amplitude, Time Step, or
Time Series) to an event:

– Alternatively, you can right-click Loading Event and choose Add Load:

– Any number of Loads can be added to an event:

• Details for each load are defined in the Details Window:

– Constant Amplitude Loads

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
16 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

– Time Step Loads

– Time Series Loads

1. For a Static, WB LS-DYNA, or Direct Transient analysis:

• You should select either a Static, WB LS-DYNA or Transient system as the Environ-
ment for the load.

• A time series file should be selected as the Input File.

2. For Modal Superposition Transient analysis where the modal combinations are calculated
within DesignLife:

• You should select a Modal system as the Environment for the load. This exposes addi-
tional fields in the Details view to collect information on the Modal Coordinate File.

• The Modal Coordinate File (MCF) can be passed in two ways:

– By environment - select a solved transient system that contains the MCF file.

– By manual file input - select the file containing modal coordinates information as the
Input File.

3. When using Ansys Motion:

• Select a Modal system containing the genCMS.rst file as the Environment.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 17
DesignLife Add-on

• The Modal Coordinate File (MCF) can be passed as explained above.

Note:

The MCF file used by DesignLife should be mass normalized. This is the default in
Mechanical.

Note:

You are loading a Modal Coordinates File (MCF) that could have a different unit system
from the .rst file of the Modal system. You therefore need to input the Units with
which the MCF was generated so that the appropriate conversion is done.

Caution:

The signs of the modal coordinates stored in the .mcf file are not unique. To ensure
the mode shapes of the .rst and .mcf files are identical, they must be generated
from the same analysis solution. Matching .rst and .mcf files from different
solutions can produce incorrect results. If the .mcf file is imported, you must verify
that it was generated from the same solution as the .rst file.

When importing either the time series file or the MCF file, you have two ways of defining how the
imported files are stored. If you want the file to be local to your machine, load it with the Input
File Definition set to an Absolute Path. If you want the file to be contained within the project,
load it as a Relative Path.

Note that if Relative Path is used, the imported file is copied to the user_files directory. If you
are importing multiple files you should therefore make sure that they are named differently.

1.3.5.2. Frequency Domain Loading Events

To specify loads for Frequency Domain Loading Events:

• Click Add Load under Loading Event to add a load of type PSD (Power Spectral Density),
Single Frequency, Frequency Range, or Sine On Random to an event:

Alternatively, you can right-click Loading Event and choose Add Load.

A frequency-based load (PSD, Single Frequency, Frequency Range or Sine On Random)

allows you to select .rst files from Harmonic and Modal systems.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
18 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

To select the .rst directly from a connected upstream system, set the RST Definition to
Environment (default). You can then choose the upstream connected environment from
which the .rst file will be selected.

If you want to load an .rst file manually, set the RST Definition to Manual. Load the file
from the Absolute Path, or load the file to the user_files folder inside the solver directory
using the Relative Path option.

Note:

Manual file selection does not allow the use of .rst files from harmonic systems.
If the RST Definition is set to Manual File, the .rst file must be from a Modal
system and a Harmonic system must be linked using the Environment or
Manual File option for the MCF Environment property.

If you select Absolute Path, the file from that exact location is consumed. If this file is
modified, the changes are consumed when solving, so ensure the required file is located at
the absolute path. If you select Relative Path, all loaded .rst files are copied to the
user_files folder. If you are loading more than one .rst file, you must therefore give
them different names, or they will be overwritten.

If a Harmonic environment is selected, the MCF Environment setting is hidden and Direct
FRF analysis will be performed.

If a Modal environment is selected, the MCF Definition setting appears. Select between or
Manual File or Environment options.

Manual File

Set the option to Manual File to import the required Modal Coordinate File (MCF).
If you want the file to be local to your machine, load it as Absolute Path. If you
want the file to be contained within the project, load it as Relative Path.

Note that if Relative Path is used, the imported file is copied to the user_files
directory. Therefore, if you are importing multiple files, make sure they are named
differently.

Note that you are loading a Modal Coordinates File (MCF) that can have different
unit systems from the rst file of the Modal system. You therefore need to input the
Units with which the MCF was generated so that the appropriate conversion is
done.

Environment

Set the option to Environment to select the linked Harmonic system from where
the MCF file is picked.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 19
DesignLife Add-on

Environment and Harmonic Step entries appear and Modal Based FRF analysis will
be performed. Select the required MCF Environment from the drop-down list
generated with all Harmonic systems.

Note:

The MCF File used by DesignLife should be mass normalized. This is the default
in Mechanical.

Caution:

The signs of the modal coordinates stored in the .mcf file are not unique. To
ensure the mode shapes of the .rst and .mcf files are identical, they must be
generated from the same analysis solution. Matching .rst and .mcf files from
different solutions can produce incorrect results. If the .mcf file is imported, you
must verify that it was generated from the same solution as the .rst file.

– If the Analysis Settings for the selected Harmonic has the Multiple Steps option
set to No, the Harmonic Step entry will be hidden, as there is just a single step.

– If the Analysis Settings for the selected Harmonic has the Multiple Steps option
set to Yes, the Harmonic Step will be visible and the list will be populated with all
the steps defined in the Harmonic Analysis Settings.

– If the Analysis Settings for the selected Harmonic has the Cluster Results option
set to Yes, you should see the following warning: Clustering frequencies in harmonic
analysis is not recommended for vibration fatigue. Check results carefully.

• For Frequency Range, Sine On Random and PSD loading types, the Frequency Selection
Method is exposed to allow you to define the method used for selecting the frequency
points of the local response PSD or sine sweep amplitude.

The following options are available:

LoadingAndFRFFrequencies

This is the default value. Use all the frequencies that appear in the loading PSD or
sine sweep amplitude and the FRF. This is the default choice because it allows peaks
in the loading and natural frequency response to be considered without loss in
resolution.

LoadingFrequencies

Use the same frequency values as the input loading PSD or sine sweep amplitudes.

FRFFrequencies

Use the same frequency values as the FE analysis (the same frequencies as the FE
Frequency Response Function). In the case of the multi-PSD input, all frequency
values, in all configured load cases from the FE input will be used.

• Details for PSD load are defined in the Details Window:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
20 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Environment

Select the system from which the .rst file will be picked for the nCode fatigue analysis.

PSD Cycle Counting Method

Select between Lalanne, Dirlik, Narrow Band, or Steinberg.

Note:

If there is more than one loading event, all PSD loads must use the same PSD
Cycle Counting Method.

Interpolation Method

Select between Linear or Logarithmic interpolation methods. The default is Logarithmic.

This will impact both the frequency while stepping through the FRF and the PSD points
defined in the table. Therefore, it will modify both the PSD points in the csv frequency
table and the InterpolationMethod in the input.dcl.

When the local response is calculated at frequencies where the FRF or PSD loading is
not defined, the necessary values are interpolated. Interpolation can be LogLog (Log-
Log) or LinLin (Linear-Linear). Note that if data is required beyond the ends of the data,
the last data point is used.

Frequency Extrapolation Method

Method for calculating results outside input frequency ranges. UseLimits is the default
value.

Select None to perform all calculations within a frequency range valid for all inputs.
Frequencies outside this range are ignored.

If you select UseLimits to include frequencies outside the range of the input data, the
last defined data point will be used.

Points used in PSD

Select between Program Controlled, in which 1024 points are used, and Manual
Definition in which you input the desired number of interpolation points.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 21
DesignLife Add-on

Table Definition

Click Apply and enter the PSD spectrum values into the table. The spectrum values
are the Frequency versus the loading squared per unit frequency. The Value in the table
depends on the loading type. The loading type can be either force, displacement, velocity,
or acceleration, but it must match the applied loading from the Harmonic analysis. For
example, if the applied harmonic loading was 1G acceleration, then the PSD spectrum
values must be defined in G^2/Hz.

The table entries cannot have negative values or multiple entries for the same frequency
value.

When selecting the PSD load, two curves are displayed in the PSD Graph window (see
below), the PSD Table and the PSD Curve:

– The PSD Table corresponds to the PSD spectrum versus the loading squared per
unit values input in the tabular data table.

– The PSD Curve corresponds to the interpolation performed on the input tabular
data points, which depends on the Interpolation Method selected, the number
of points used in PSD, and the input tabular data.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
22 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Use Static Load Case

If Use Static Load Case is set to Yes. Select the static environment and its step from
which to consider the static load case.

• Details for Single Frequency load are defined in the Details Window:

Environment

Select the system from which the .rst file will be picked for the nCode fatigue
analysis.

Frequency (Hz)

Set the frequency in Hz to a float positive value. The default value is 10 Hz. This
parameter corresponds to the SineDwellFrequency parameter in nCode.

Exposure Duration (sec)

Set the exposure duration in seconds to a float positive or equal to a zero value.
The default value is 600 sec. This parameter corresponds to the SineDwellDura-
tionSeconds parameter in nCode.

Amplitude (g)

Set the amplitude in g to a positive float value. This parameter is used to create the
table file containing the Frequency [Hz] versus Amplitude [g] values that the Single
Frequency load uses.

Use Static Load Case

If Use Static Load Case is set to Yes, select the static environment and its step
from which to consider the static load case.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 23
DesignLife Add-on

• Details for Frequency Range load are defined in the Details Window:

Environment

Select the system from which the .rst file will be picked for the nCode fatigue
analysis.

Number of Sweeps

How many times the spectrum of frequencies will be swept.

Sweep Rate

The velocity of the frequency sweep, defined in the units set in the Sweep Type
property.

Sweep Type

The type of units that define the Sweep Rate. Choose between Linear (Hz/sec),
Log (sec/decades), and Log (octaves/minute).

Interpolation Method

Choose between Linear or Logarithmic interpolation methods.

The default value is Logarithmic. This will impact both the frequency stepping
through the FRF and the PSD points defined in the table. Therefore, it will modify
both the PSD points in the csv frequency table and the InterpolationMethod
in the input.dcl.

When the local response is calculated at frequencies where the FRF or PSD loading
is not defined, the necessary values are interpolated. Interpolation can be LogLog
(Log-Log) or LinLin (Linear-Linear). Note that if data is required beyond the ends of
the data, the last data point is used.

Use Static Load Case

If Use Static Load Case is set to Yes, select the static environment and its step
from which to consider the static load case.

• Details for Sine On Random load are defined in the Details Window:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
24 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Environment

Select the system from which the .rst file will be picked for the nCode fatigue
analysis.

Exposure Duration (sec)

Set the exposure duration in seconds to a float positive or to a zero value. This
parameter corresponds to the ExposureDuration parameter in the input.dcl.

Interpolation Method

Select between Linear or Logarithmic interpolation method. The default value is

Logarithmic.

This will impact both the frequency stepping through the FRF and the PSD points
defined in the table. It will therefore modify both the PSD points in the csv frequency
table and the InterpolationMethod in the input.dcl.

When the local response is calculated at frequencies where the FRF or PSD loading
is not defined, the necessary values are interpolated. Interpolation can be LogLog
(Log-Log) or LinLin (Linear-Linear). Note that if data is required beyond the ends of
the data, the last data point is used.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 25
DesignLife Add-on

Table Definition

This corresponds to the PSD definition that will be used to generate the frequency
table csv file.

Sine On Random Frequencies [Hz]

This is a string property that contains a delimited list of sine tone frequencies to
superimpose on the Random PSD for SineOnRandom vibrations.

This list must be the same length as the SineAmplitudes list. The values from the
two lists are used in pairs. The default value is not set.

Sine On Random Amplitudes [Value]

This is a string property that contains a delimited list of sine tone amplitudes to
superimpose on the Random PSD for SineOnRandom vibrations.

This list must be the same length as the SineFrequencies list. The values from the
two lists are used in pairs. The default value is not set.

Note:

For the Sine On Random Frequencies and Sine On Random

Amplitudes value lists, comma ',' can be used as the value separator
unless working in a locale where comma is used as the decimal
separator, in which case semi-colon ';' must be used instead.

Sine On Random Cycle Counting Method

This property defines the underlying assumption to use in the cycle counter. The
narrow band approach tends to be conservative and is the default. The broad band
method is analogous to Gaussian random noise, is less conservative and is more in
agreement with results obtained from time domain equivalent calculations. The
default value is NarrowBand.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
26 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Use Static Load Case

If Use Static Load Case is set to Yes, select the static environment and its step
from which to consider the static load case.

Note:

If the Analysis Domain is set to Time based, only Time Domain loads are allowed. If
the Analysis Domain is set to Frequency based, only Frequency Domain loads are al-
lowed.

Note:

If the Loading Type is set to PSD, all loading events must be PSD too. PSD Loading
events cannot be combined with other types of loading events. In addition, all PSD
loading events, must have the same PSD Cycle Counting Method.

• The EntityDataType is a property passed to the nCode solver through the input.dcl file that
defines the type of results data that will be recovered from the input FE file(s).

Possible values are as follows:

Vibration

Vibration results are required to support the Vibration Load Provider (p. 35) in order to
make fatigue calculations based on PSD, swept-sine, sine-dwell, sine-on-random or multi-
PSD loadings. The nCode solver looks in the FE results for a stress frequency response
function (FRF). This takes the form of a complex stress response to unit excitation at a
number of frequencies. Because the FRF will be combined with a PSD or swept-sine
definition in the Vibration Load Provider to generate the local response, the unit excit-
ation and the PSD of swept-sine should have consistent units. For example, for a PSD
loading, if the PSD is defined in acceleration units of g2/Hz, then the FE analysis should
provide the frequency response to an excitation of amplitude of 1g across the frequency
range.

The EntityDataType is set to Vibration when consuming harmonic RST results for Stress,
Strain, Gray Iron, Solid Seam Weld, Spot Weld and Short Fiber Composites analysis.

ModalVibration

Vibration results are required to support the Vibration Load Provider in order to make
fatigue calculations based on PSD, swept-sine, sine-dwell, sine-on-random or multi-PSD
loadings. The nCode solver can use a stress frequency response function (FRF) directly
(see Vibration above) but the FRF can also be calculated from modal stress results and
this can be a more efficient solution.

A modal stress result consists of stress for each mode (real) and when combined with a
set of modal participation factors (complex) is used to calculate the complex FRF. The
modal stress result will typically be a much smaller result than the FRF, having stress
results only for each mode of the system. The required frequency resolution of the FRF
is obtained from the resolution of the modal participation factors.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 27
DesignLife Add-on

The EntityDataType is set to ModalVibration when consuming modal RST results and
harmonic MCF results for Stress, Strain, Gray Iron, Solid Seam Weld, Spot Weld and Short
Fiber Composites analysis.

ForceVibration

This option is used for Shell Seam Weld analyses based on vibration loading with forces
and moments.

The EntityDataType is set to ForceVibration when consuming harmonic RST results

for Shell Seam Weld analysis.

ModalForceVibration

This option is used for Seam Weld analyses based on vibration loading with forces and
moments. This is the modal equivalent of ForceVibration for seam welds.

A modal force result consists of forces for each mode (real) and when combined with a
set of modal participation factors (complex) is used to calculate the complex FRF. The
modal force result will typically be a much smaller result then the FRF, having force
results only for each mode of the system. The required frequency resolution of the FRF
is obtained from the resolution of the modal participation factors.

The EntityDataType is set to ModalForceVibration when consuming modal RST results

and harmonic MCF results for Shell Seam Weld analysis.

1.3.5.3. Comparison of Frequency Domain Add-On Results to Standalone

DesignLife Results
When comparing the add-on results in the frequency domain to standalone DesignLife results, the
settings for the standalone DesignLife Vibration Generator Glyph must be compatible. This section
describes how to ensure that compatibility for each vibration loading type.
1.3.5.3.1. Single Frequency Loads
1.3.5.3.2. Frequency Range Loads
1.3.5.3.3. Consistent Acceleration Loading
1.3.5.3.4. Vibration Generator Properties
1.3.5.3.5. Vibration Load Provider
1.3.5.3.6. DesignLife SineDwell Using Vibration Generator
1.3.5.3.7. DesignLife SineDwell Using DesignLife Properties
1.3.5.3.8. DesignLife SineOnRandom Using Vibration Generator
1.3.5.3.9. DesignLife SineOnRandom Using DesignLife Properties
1.3.5.3.10. Vibration Generator to DesignLife for Frequency Range (Sine Sweep)

A fundamental understanding of standalone DesignLife is necessary to understand these settings.

The information in this section does not apply to using the add-on.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
28 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

1.3.5.3.1. Single Frequency Loads

Below is an example loading for Single Frequency analysis in the embedded add-on.

This is the equivalent DesignLife Integrated Vibration Generator configuration. In the Advanced
tab, define the Type as SineDwell.

The table defined is as below.

The main difference in the two approaches is the Exposure Duration property, which is not ex-
plicitly defined in the Integrated workflow. The general rule is to multiply the Frequency and

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 29
DesignLife Add-on

Exposure Duration from the add-on load provider and use the product as input to the Number
of Cycles field in the Vibration Generator Glyph.

Go to the Vibration Load in the Analysis Glyph and ensure that the LoadingConfigSource field
is set to MetaData.

1.3.5.3.2. Frequency Range Loads

Below is an example of Frequency Range loading in a vibration fatigue analysis in the embedded
add-on.

This is the equivalent DesignLife Integrated Vibration Generator configuration. In the Advanced
tab, define the Type as SineSweep2.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
30 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

In the Vibration Generator Configuration, additional inputs are required to the StartFrequency
and EndFrequency fields. This would correspond to the frequency range defined in the upstream
Harmonic analysis. The AdditionalNumberOfSweeps field is not equivalent to the Number of
Sweeps field in the embedded add-on load. The equivalence depends on SweepType used (see
the sections below for more information).

Go to the Load Provider option in the Analysis Glyph and set LoadConfigSource to Metadata.

1.3.5.3.3. Consistent Acceleration Loading

The excitation applied in the steady state dynamics FE analysis as a frequency sweep with ‘unit’
magnitude

• Force

• Acceleration

• Displacement

must match both model units and the input PSD units.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 31
DesignLife Add-on

PSD g2/Hz

9810 mm/sec2

9.81 m/sec2

386.4 in/sec2

32.2 ft/sec2

PSD (mm/sec2)2/Hz

1.0 mm/sec2

0.001 m/sec2

PSD (m/sec2)2/Hz

1000.0 mm/sec2

1.0 m/sec2

PSD (in/sec2)2/Hz

25.4 mm/sec2

1.0 in/sec2

PSD and Swept Sine Inputs

Multicolumn Input

• CSV File

– PSD

– Swept Sine

– Sine Dwell

• EXCEL

PSD Input

• Vibration Generator

– PSD

– Swept Sine

– Swept Sine 2

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
32 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

• ASCII Translate

CSV Multicolumn Inputs

• Units used for display, not for conversion

• Data values used directly by DesignLife

1.3.5.3.4. Vibration Generator Properties

Advanced tab

All properties on this form are passed out as metadata (as described in the image above):

General

• SineSweep2 - Sets the vibration type

Histogram Output

• StartFrequency

• EndFrequency

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 33
DesignLife Add-on

• FrequencyStep

Sinesweep2

• TestDuration

• AdditionalNumberOfSweeps

• SweepType

• SweepRate

• InterpolationMethod

• TestType

Vibration Properties tab

Data in the Vibration Properties tab is set manually and the data in this table is passed out as
metadata as a packet named VibrationTables.

This table is defined on the Advanced tab by:

• Type = SineSweep2

• VibrationTable = PropertiesTab

• TestType = Acceleration (g)

SineSweep2 Metadata Example:

<Set name="VibrationGenerator1_Properties">
<Item name="AdditionalNumberOfSweeps" type="Long" value="0"/>
<Item name="EndFrequency" type="Float" value="1000"/>
<Item name="FrequencyStep" type="Float" value="1"/>
<Item name="InterpolationMethod" type="String" value="Log"/>
<Item name="StartFrequency" type="Float" value="1"/>
<Item name="SweepRate" type="Float" value="1"/>
<Item name="SweepType" type="String" value="OctavesPerMinute"/>
<Item name="TestDuration" type="Float" value="600"/>
<Item name="TestType" type="String" value="Acceleration (g)"/>
<Item name="Type" type="String" value="SineSweep2"/>
<Item name="VibrationTable" type="String" value="PropertiesTab"/>
<Item name="XMLTables" type="String" value=“VibrationGenerator1_Properties"/>

<VibrationTables Version=""1.0"">
<Tables>

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
34 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

<SineSweep2>
<SineSweep2Item Amplitude=""0.1"" Frequency=""1""/>
<SineSweep2Item Amplitude=""5"" Frequency=""10""/>
<SineSweep2Item Amplitude=""20"" Frequency=""100""/>
<SineSweep2Item Amplitude=""10"" Frequency=""1000""/>
</SineSweep2>
</Tables>
</VibrationTables>

SineSweep2 Acceleration Histogram

The histogram output is controlled by the following Advanced tab properties:

• StartFrequency

• EndFrequency

• FrequencyStep

The amplitudes for the histogram are obtained from the table on the Vibration Properties tab.

• Any output frequencies not covered by the table will be set to zero.

• These zero amplitudes will generate an error if the InterpolationMethod is set to Log.

1.3.5.3.5. Vibration Load Provider

The FRF can be paired up with metadata from Vibration Generator (see below).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 35
DesignLife Add-on

When LoadingConfigSource is set to Metadata (see below), the swept sine definition in DesignLife
is calculated from the Vibration Generator metadata properties.

The histogram from the Vibration Generator is not used, the sweep range is defined by the XM-
LTable in the metadata.

When LoadingConfigSource is set to Custom, the swept sine definition in DesignLife is calculated
from the Vibration Generator histogram and properties set on the Advanced tab.

When the LoadingConfigSource is switched from Custom to Metadata and then back to Custom,
load provider properties are set to those calculated from the Vibration Generator settings.

If the frequency ranges defined on the Advanced tab and Vibration Properties tab of the Vibra-
tion Generator were not the same, a Custom run and a Metadata run will generate different
results.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
36 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Swept Sine Sweep Rate Calculations

Linear HZ per Sec

Sweep_Rate = (fmax – fmin)/Time(sec)

Log Secs per Decade

Sweep_Rate = Time(sec)/( log(fmax) – log(fmin) )

Log Octaves per Min

Sweep_Rate = ( ( log(fmax) – log(fmin))/log(2) )/Time(min)

where,

Time = total duration of test

fmin = starting frequency of sweep in Hz

fmax = ending frequency of sweep in Hz

Sweep_Rate = sweep rate in sweep rate type

1.3.5.3.6. DesignLife SineDwell Using Vibration Generator

SineDwell properties are set for:

• Amplitude

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 37
DesignLife Add-on

• Frequency

• Number of Cycles

These are passed out as metadata, with no histogram data output.

• Amplitude from metadata

Advanced Tab

LoadingConfigSource must be set to Metadata.

The analysis uses amplitude, frequency and number of cycles from the Vibration Generator
metadata.

The DesignLife load provider must be set to the appropriate amplitude, SineDwellFrequency
and SineDwellDurationSeconds.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
38 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

1.3.5.3.7. DesignLife SineDwell Using DesignLife Properties

Edit Loading Tab

The FRF (Frequency Response Function) is paired up with acceleration data. Load data can be
multicolumn or histogram curves of acceleration amplitude versus frequency. The dwell frequency
must be inside the range of the sine sweep contained in the load data.

Advanced Tab

SineDwell Properties

• Frequency

• Duration

The duration is the summation of:

• SineDwellDurationSeconds

• SineDwellDurationHours

• SineDwellDurationDays

• SineDwellDurationYears

When LoadConfigSource is set to Custom, the dwell amplitude is determined from the sine
sweep loading selected on the Edit Loading tab.

SineDwellDurationSeconds = (Number of Cycles)/(Frequency (Hz))

where Number of Cycles & and Frequency are set in the Vibration Generator.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 39
DesignLife Add-on

1.3.5.3.8. DesignLife SineOnRandom Using Vibration Generator

PSD (Power Spectral Density) is defined in Vibration Properties.

• Metadata 4 frequency points

• Histogram 1024 frequency points

SineFrequencies and SineAmplitudes are output as metadata.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
40 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Advanced Tab

PSD is input from metadata containing 4 frequency steps.

Amplitudes and frequencies of sine tones are input as metadata.

ExposureDuration and CycleCountingMethod are DesignLife properties.

The default frequency selection method is used if:

• Direct FRF did not contain well spaced frequencies

• Answers were significantly different from the Custom solution

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 41
DesignLife Add-on

Frequency Steps used in Solution

In the example below, the default frequency selection method was initially used, but the PSD
frequency steps from metadata and the FRF frequency steps from the harmonic solution did not
have enough resolution to define the stresses.

Switching the FrequencySelectionMethod to UserDefined, and specifying a 1 Hz frequency

step corrected the issue (see below).

Advanced Tab

The lack of resolution in the frequency steps (above) was not immediately obvious.

Use of a modal FRF with fine frequency spacing is recommended.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
42 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

1.3.5.3.9. DesignLife SineOnRandom Using DesignLife Properties

Though the loading input is still from the Vibration Generator, with the Custom setting selected
the only input is the PSD as a histogram.

This makes the default frequency selection method an adequate choice.

As before, the ExposureDuration and CycleCountingMethod are both DesignLife properties.

1.3.5.3.10. Vibration Generator to DesignLife for Frequency Range (Sine Sweep)

Below is the table conversion to see the DesignLife properties when setting the Vibration Gener-
ator.

Linear HZ per Sec

Sweep_Rate = (fmax – fmin)/Time(sec)

Log Secs per Decade

Sweep_Rate = Time(sec)/( log(fmax) – log(fmin) )

Log Octaves per Min

Sweep_Rate = ( ( log(fmax) – log(fmin))/log(2) )/Time(min)

where,

Time = total duration of test

fmin = starting frequency of sweep in Hz

fmax = ending frequency of sweep in Hz

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 43
DesignLife Add-on

Sweep_Rate = sweep rate in sweep rate type

See examples of conversions below:

1. Linear (Hz/sec)

2. Log (sec/decades)

3. Log (octaves/minute)

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
44 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

1.3.6. Materials Assignment

Include a Materials Assignment object to modify the material used in the fatigue calculation. Be
aware that the upstream systems connected to nCode will still use the material defined in Engineering
Data. Only the material parameters for the fatigue calculation within nCode system will be modified.

Note:

When using the DesignLife add-on, Young's Modulus and Tensile Ultimate Strength
properties must be defined for all materials in the engineering data. No comma symbols
are allowed in the material name.

1. Right-click Materials and choose Modify Material Parameters.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 45
DesignLife Add-on

Figure 1.3: Modify Material Parameters

2. Scope the part that you would like to analyze with a different material. If elements have more
than one Materials Assignment applied to them, the first Material Assignment defined in the
tree will be used.

The Materials Assignment properties can be defined from a material used in the analysis, defined
within Engineering Data (Manual) or picked from an nCode material *.mxd database (Database).

Manual Material Properties Definition

3. Pick a Based on Material from engineering data to base the new material on an existing material's
data.

4. For a Strain Fatigue Type analysis, set the Strength Coefficient, Strength Exponent, Ductility
Coefficient, Ductility Exponent, Cyclic Strength Coefficient, Cyclic Strain Hardening Exponent,
Young's Modulus, Poissons's Ratio, and Tensile Ultimate Strength of the new material.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
46 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Figure 1.4: Materials Properties for Strain Analysis

When the material properties are fully defined, the Strain-Life relationship is represented. Shown
below is the Coffin-Manson-Basquin formula, defining the relationship between strain amplitude
and the number of cycles to failure :

The elastic life is given by:

where is the strength coefficient, E is the Young's Modulus and b is the strength exponent.

The plastic life is given by:

where is the ductility coefficient and c is the ductility exponent.

The total life is given by the sum of the elastic and plastic life:

Graphically, this is displayed as shown below:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 47
DesignLife Add-on

Fatigue damage is predicted in the same way as for the S-N method - the damage due to an indi-
vidual cycle is calculated by looking up the strain amplitude of that cycle on the curve to find the
number of reversals to failure 2Nf. The damage assigned to that cycle is then 1/Nf.

5. For a Stress Fatigue Type analysis, set the S-N Curve, Stress Offset, Scale Factor, Young's
Modulus, Poissons's Ratio, and Tensile Ultimate Strength of the new material.

For Stress Analysis, the nCode Multicurve Stress-Life Parameters are set to User Defined and
populated from engineering data (if defined) when the Materials Assignment is created.

To import an S-N Curve, select a *.csv file containing the cycles data in the first column and
the alternating stress in the second column. Multiple curves must be imported separately.

If nCode Multicurve Stress-Life Parameters are not defined in the engineering data, the definition
is set to Program Controlled and default values for Nfc, SEIs, and Ne are used (see below).

Parameter Description Defau

Nfc Numerical fatigue cutoff life, in cycles. Beyond this life, damage will be assumed 1e+30
to be zero.
SEIs Standard error of log10(stress). 0.0540
Ne Endurance limit. This is the specified life in cycles. The main function of this is to 1e+7
define the point on the S-N curves where surface finish corrections are applied.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
48 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Figure 1.5: Materials Properties for Stress Analysis

Each defined S-N curve is displayed as shown below:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 49
DesignLife Add-on

6. Set the nCode Material Type to one of Grey Cast Iron, Nodular Cast Iron, Malleable Cast Iron,
Cast Steel, Steel, Aluminum, and Cast Aluminum.

Note:

When calculating Stress Life or Safety Factor analysis, the material definition should be
consistent for all the materials used in the model. If a material uses SN Curve-defined
Mean Stress, care should be taken to ensure that for all materials assigned in the
analysis, SN Curves are defined using Mean Stress and likewise for R-Ratio (see Fatigue
Material Properties for more information).

Materials Database Definition

As an alternative to the manual method above, material properties can be selected from an nCode
material database.

The default materials applied for the analysis are taken from the iceflow_standard.mxd
database, which can be found in the mats folder in the nCode installation. If the Analysis Type
is Solid or Shell Seam Weld, the default material is seam_steel. If the Analysis Type is Short
Fiber Composite, the default material is Valox 508 GF30.

To modify the default material for Stress, Strain, Gray Iron, Safety Factor, Short Fiber Composite,
Solid or Shell Seam Weld analysis:

7. Insert a Materials Assignment object.

8. In the case of Stress Life analysis, the S-N Curve Definition property must first be defined as
either Mean Stress, R-Ratio, or Temperature.

9. In the case of Strain Life analysis, the S-N Curve Definition property must first be defined as
either Strain or Temperature.

10. Set the Database by selecting the *.mxd database file where all the nCode materials are defined.

This file is copied to the current directory. The DesignLife add-on filters the materials found in
this database.

For Stress Life and Safety Factor, it lists those that are valid for Stress Life analysis (nCodeSN-
MeanStressCurveContainer or nCodeSNRRatioCurveContainer type).

For Strain Life, it lists those that are valid for EN analysis (nCodeENMatData type).

For Solid and Shell Seam Weld, it lists those that are valid for Seam Weld analysis
(nCodeSNSeamWeldMatData type).

For Short Fiber Composite, it lists those that are valid for Short Fiber Composite analysis
(nCodeSFCBasquinCurveContainer type).

For Stress Life or Strain Life, if Temperature is selected, it lists those that are valid for temperature-
dependent analysis (nCodeSNTemperatureCurveContainer or nCodeENTemperature-
CurveContainer types). In this case, the Default Temperature parameter for the material will
also be exposed and assigned to the scoped material assignment parts.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
50 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

11. Select the new Material.

Note:

If the database material selected is a mean stress curve that does not contain mean
stress curve defined at zero, you will get an nCode solver error stating that the Multi
curve material contains no curve with mean stress. To avoid this, ensure the Mean Stress
Correction in the analysis settings is set to Interpolate.

Surface Finish and Surface Treatment Settings

Surface finish and treatment can have a significant effect on fatigue behavior. Rough surface finishes
due to machining marks, for example, will in general reduce the fatigue strength, whereas surface
treatments are often applied to increase the fatigue strength.

In nCode, surface finish and treatment effects are modeled in the S-N and E-N engines by means
of a single surface factor Ksur. This works in a different way from the scale factor described above,
with which it should not be confused. The surface factor is used to adjust the material curve. The
application is slightly different for the S-N and E-N methods, but the basic principle is the same—the
surface factor is applied to the fatigue strength of the material in the high cycle (long-life) regime,
but the effect reduces in the low cycle (short-life) regime. The details of the application of the
surface factor are given in the DesignLife Help, with the sections describing the S-N and E-N
analysis engines. Ksur is the product of three factors, which can be defined via the material map.
Each of these has default value of 1.

Ksur = Ktreatment x Kuser x Kroughness

Where Ktreatment is the Surface Treatment Factor, Kuser is the User Surface Factor and Kroughness
is the Roughness factor.

12. Set the Surface Treatment Factor to adjust the fatigue strength to take into account surface
treatment. A factor > 1 will result in an improvement in fatigue strength. The Surface Treatment
Factor should be a positive float number. The default value is 1.0.

13. Set the User Surface Factor to adjust the fatigue strength for any unspecified reason. A factor >
1 will result in an improvement in fatigue strength. The User Surface Factor should be a positive
float number. The default value is 1.0.

14. The Roughness factor is defined through the Surface Finish property.

If one of the surface roughness descriptions is selected (Polished, Ground, Machined, Poor Ma-
chined, As Rolled, or As Cast), the value for the surface roughness is as shown in the table below.

Condition Rz(μm)
Polished 0
Ground 12.5
Machined 100
Poor Machined 200
As Rolled 200

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 51
DesignLife Add-on

Condition Rz(μm)
As Cast 200

If the Surface Finish is set to Enter Surface Roughness, the Surface Roughness [microm] setting
is exposed. The Surface Roughness Factor will then be calculated based on the specified value.

If the Surface Finish is set to Enter K Roughness, the Roughness Factor setting is exposed to
be set directly, based on your experience or on experimental evidence.

Materials Assignment for Gray Iron Analysis

For a Gray Iron type analysis, set the nCode Gray Cast Iron Parameters. These parameters are
automatically populated from engineering data. If the selected base material does not contain the
Gray Iron material properties, they must be defined manually (see table below).

The Gray Iron dataset consists of the following properties:

nCode Parameter Name Description

UTS Ultimate Tensile Strength. This is required to apply the static failure
criterion.
E0 Tangent modulus at zero
nt Tensile strain hardening exponent
Kt Tensile strain hardening coefficient
Nc Compressive strain hardening exponent
Kc Compressive strain hardening coefficient
mc Compressive secant slope
mu Unloading secant slope
Ks Damage curve co-efficient
ns Damage curve exponent
RC Damage curve cutoff
SD Standard error of log life
mt Tensile secant slope

1.3.7. Solve
When solving, the input file used to run nCode is created automatically by the add-on. The nCode
solver is triggered in batch mode, so you may see the nCode executable (dtproc.exe) command
window open and close once the fatigue calculation is completed.

nCode supports reading of various FE files, including .rst and .d3plot. The import of results is
performed by translating the FE data into an intermediate form, stored in a file with a .fei extension.
The creation and use of this file is generally invisible to the user and the file is created or re-created
as needed. If you change a configuration that does not impact the .fei, then the existing file from
the previous simulation will be reused, saving computational time.

If the nCode solver experiences an error, select Solution Information to see more details.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
52 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

1.3.8. Post-processing
These operations are available in post-processing:
1.3.8.1. Most Damaged Tabular Data and Series Output History
1.3.8.2. Post-processing Static Failure
1.3.8.3. Effect of Stress Averaging on Fatigue Results
1.3.8.4. Damage and Rainflow Matrix Plots
1.3.8.5. Solid Seam Weld Life and Damage Vector Results

• You can add a result by selecting the Ansys nCode DesignLife toolbar with Solution active
in the tree:

• Alternatively, you can right-click Solution, choose Insert, and pick a result type.

• An entire loading history can be post-processed, or events may be post-processed individually

by selecting Event (default = entire load history).

• Use the Details Window to specify the maximum life or maximum damage to be displayed
in contour plots. This can be used to create more discretized contour plots:

• A result can be exported by clicking Export:

• Other Results: The Ansys nCode DesignLife solver returns the life and damage results for all
analysis types. In addition to life and damage, other results such as Alternating Stress, Mean
Stress, and Minimum and Maximum Stress are returned depending on the analysis domain
and type. Once the solution is achieved, insert an Other Results object to post-process and

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 53
DesignLife Add-on

display the additional results. Select the desired results to display from the Result options
menu.

1.3.8.1. Most Damaged Tabular Data and Series Output History

Tabular Data
When you select a result that has been previously evaluated, the Most Damaged tabular data is
displayed (see Figure 1.6: Most Damaged tabular data (p. 54)).

• This tabular data displays the most damaged Node or Element IDs, displaying all results re-
turned by the Ansys nCode DesignLife solver for the corresponding node or element.

• By default, the five most damaged Node or Element IDs are filtered. If you require a different
number of IDs to be filtered, modify the Most Damaged Ids to Display parameter.

• If you select a NodeId or ElementId in the tabular data, the corresponding node or element
will be selected and highlighted in green in the graphics panel.

• For Shell Seam Weld analysis, the Shell Layer, Seam Weld Location and Seam Weld Type
results are also displayed.

Figure 1.6: Most Damaged tabular data

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
54 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Series Output History

You can choose to display the Series Output History for each of the Most Damaged Ids displayed.

The Show Series Output History option in the Definition section for a Life Loading Event is set
to No by default. Set this to Yes to display the Series Output History.

When setting the Show Series Output History to Yes. The DesignLife add-on gathers the list of
requested Most Damaged Ids and sends the list of elements or nodes to extract for each of them,
using the TimeSeriesOutput in the case of the Time domain and the VibrationPSDOutput in the
case of the Frequency domain.

The Series Output History is supported for both Time and Frequency domain and for Stress,
Strain, Gray Iron, Shell Seam Weld, Solid Seam Weld, and Short Fiber analysis types.

For the Time Domain case (see Figure 1.7: Series Output History: Time domain case (p. 55)), for
each node or element, a graph for the combination of loading events is created as the Event pro-
cessing setting for the frequency domain is set to All. In this case, the x-axis corresponds to the
number of cycles.

Figure 1.7: Series Output History: Time domain case

For the Frequency Domain case (see Figure 1.8: Series Output History: Frequency domain
case (p. 55)), for each node or element, a graph for each loading event is created as the Event
processing setting for frequency domain is set to independent Loading Events. In this case, the
x-axis corresponds to the frequency range.

Figure 1.8: Series Output History: Frequency domain case

Displaying a Single Time Series Output

By default, for a Series Output History, all the output .csv files generated by nCode are plotted.
However, single graphs can be plotted by selecting the required entry from the Series Output

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 55
DesignLife Add-on

History drop-down menu (see Figure 1.9: Selecting a specific Time Series Output (p. 56)). Graphs
for the corresponding node and loading event can be displayed independently.

Figure 1.9: Selecting a specific Time Series Output

Figure 1.10: Series Output History: Single output display

Extracting Peak Information

To be able to extract the peak information from a particular graph, you can hover over the specific
graph point and a label with the corresponding x and y-information is displayed.

Figure 1.11: Series Output History: Extracting peak information

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
56 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

You can filter the x-axis minimum and maximum ranges to visualize the area of interest by setting
the Output History X Axis Minimum and Output History X Axis Maximum values (see below).

Figure 1.12: Series Output History: Minimum and maximum values

1.3.8.2. Post-processing Static Failure

For Time Based, Stress-Life Analysis (SN), the Static Failure Damage is set to 1.234e29 in the in-
put.dcl file used by nCode solver.
SetProperty("SNEngine_Fatigue",StaticFailureDamage,"1.234E29")

1.3.8.2.1. Post-Processing Static Failure for Damage and Life Results:

If "Static Failure" is detected, Mechanical displays a warning message:

Calculated alternating stress in some areas exceeded the UTS, which indicates
Static Failure. For those areas, Life is set to the Static Failure Life and Damage
is set to the Static Failure Damage; plotted as purple contours.

The purple band in the legend, corresponding to the Static Failure Life or Static Failure Damage
value, represents all the areas where Static Failure is reported.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 57
DesignLife Add-on

Figure 1.13: Example of Life result where the purple band corresponds to the Static Failure

Figure 1.14: Example of Damage s where the purple band corresponds to the Static Failure

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
58 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

1.3.8.2.2. Damage Result - Maximum Damage Displayed

The next color band is represented by red. The value of the red band corresponds to the Maximum
Damage Displayed (Case 1) or the maximum damage calculated (if it is less than the limit of the
Maximum Damage Displayed (Case 2).

Case 1 — In the figure below, the Maximum Damaged Displayed is set to 1. However, the
Maximum Damage calculated is of 977.1. Therefore, Mechanical issues the following warning
message:

Calculated damage in some areas is above the specified maximum damage.

As you restricted the Maximum Damaged Displayed to 1, all values above were set to 1 and
displayed in red.

Figure 1.15: Calculated damage in some areas is above the specified maximum damage

Case 2 — In the figure below, the Maximum Damage Displayed is set to 1e4. The warning
message is no longer displayed, as the limit is not reached. The Maximum Damage Displayed
was set to 1e4, while the maximum calculated is 977.1.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 59
DesignLife Add-on

Figure 1.16: Maximum Damage display limit not reached

1.3.8.2.3. Life Result - Minimum Life Displayed

The next band color is represented by red. The value of the red band will correspond to the
Minimum Life Displayed (Case 1) or the Minimum Life calculated (if it is higher than the limit
of the Minimum Life Displayed (Case 2).

Case 1 — In the figure below, the Minimum Life Displayed is set to 700. However, the Minimum
Life calculated is of 614.4. Therefore, Mechanical issues the following warning message:

Calculated life in some areas is below the specified minimum life.

As the user restricted the Minimum Life Displayed to 700, all values below were set to 700 and
displayed in red.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
60 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Figure 1.17: Calculated life in some areas is below the specified minimum life

Case 2 - In the figure below, the Minimum Life Displayed is set to 1. The warning message is
no longer displayed, as the limit is not reached. The Minimum Life Displayed was set to 1, while
the maximum calculated is 614.4.

Figure 1.18: Minimum Life display limit not reached

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 61
DesignLife Add-on

1.3.8.3. Effect of Stress Averaging on Fatigue Results

The calculated fatigue results using the DesignLife Add-on can differ from those calculated using
the integrated/standalone Ansys nCode DesignLife interface, because the nodal stresses may differ.

The integrated/standalone DesignLife interface calculates the surface nodal stresses by averaging
the stresses from all elements that share that node. However, the DesignLife Add-on only includes
the stresses from elements that have a face on the surface. The nodal stress averaging method
used by the DesignLife Add-on is consistent with the method used by Mechanical. For refined, well-
shaped meshes, the effect of the nodal stress averaging method should be minimal. The effect can
be more substantial for poor quality meshes, particularly those with tetrahedral elements.

Differences caused by stress averaging

The DesignLife Add-on and the integrated/standalone Ansys nCode DesignLife interfaces use the
same fatigue solver. If the settings and nodal stresses are identical, the calculated fatigue results
will be identical. However, the different interfaces use different stress averaging algorithms which
can produce different nodal stresses which will then produce different fatigue results.

This simple test case demonstrates the issue with stress averaging methods. It is a simple cantilever
beam. The nodes in the center portion of the top face are saved in a Named Selection (top_face).
The fatigue calculations use the SN method, fully reversing Constant Amplitude loading, and the
signed VonMises stress. You can create a hex or tet mesh by suppressing/un-suppressing the mesh
method.

Hex Mesh
If a hex mesh is used, the maximum calculated alternating stress in the top_face is 45 ksi for the
add-on, the integrated/standalone interfaces, and the Mechanical Fatigue Tool (FT). The minimum
calculated fatigue life is 9999 cycles for all interfaces.

Figure 1.19: Hex mesh - Mechanical Fatigue Tool - Top Face Life

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
62 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Figure 1.20: Hex mesh - Mechanical Fatigue Tool - Top Face Equivalent Alternating Stress

Figure 1.21: Hex mesh - DesignLife Add-on - Top Face Life

Figure 1.22: Hex mesh - DesignLife Add-on - Top Face Equivalent Alternating Stress

Figure 1.23: Hex mesh - DesignLife Standalone - Top Face Life

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 63
DesignLife Add-on

Figure 1.24: Hex mesh - DesignLife Standalone - Top Face Equivalent Alternating Stress

Tet Mesh
If a tet mesh is used, the maximum calculated alternating stress is 45.02 ksi for the add-on, 45.11
ksi for the integrated/standalone interfaces, and 44.97 ksi for the FT. The minimum calculated fatigue
life is 9982 for the add-on, 9909 for the integrated/standalone interface, and 10019 for the FT. The
interfaces produce different fatigue results because they calculate slightly different nodal stresses.

Figure 1.25: Tet mesh - Mechanical Fatigue Tool - Top Face Life

Figure 1.26: Tet mesh - Mechanical Fatigue Tool - Top Face Equivalent Alternating Stress

Figure 1.27: Tet mesh - DesignLife Add-on - Top Face Life

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
64 of ANSYS, Inc. and its subsidiaries and affiliates.
 Using the DesignLife Add-on

Figure 1.28: Tet mesh - DesignLife Add-on - Top Face Equivalent Alternating Stress

Figure 1.29: Tet mesh - DesignLife Standalone - Top Face Life

Figure 1.30: Tet mesh - DesignLife Standalone - Top Face Equivalent Alternating Stress

Conclusion
For surface stresses, the integrated/standalone DesignLife interface calculates the nodal stress by
averaging the stress from all elements that share that node. This averaging scheme is similar to the
averaging scheme used by Mechanical APDL Full graphics. However, the add-on interface only av-
erages the stress from elements that have a face on that surface. This averaging scheme is similar
to the averaging schemes used by Mechanical APDL Power graphics and Mechanical.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 65
DesignLife Add-on

For a refined, well-shaped mesh using hex elements, the averaged surface nodal stresses should
be almost identical regardless of the averaging scheme. Thus, for those types of meshes, the calcu-
lated DesignLife fatigue results from the add-on and the integrated/standalone interface (and the
FT) should be almost identical. However, for coarse tet meshes, the averaged nodal stresses can be
affected by the averaging scheme. Thus, the calculated fatigue results may be different.

In meshes where the averaging scheme affects the nodal stresses (and therefore the fatigue results),
you can expect the add-on results to be more accurate than the integrated/standalone results.
However, a large difference in the fatigue results between the add-on and the integrated/standalone
interfaces would indicate a poor quality mesh.

1.3.8.4. Damage and Rainflow Matrix Plots

Display the Damage Matrix or Rainflow Matrix by picking a node in the graphics window and
clicking one of the Matrix icons in the Ansys nCode DesignLife toolbar.

Conditions to include a Matrix Plot: If any of these conditions are not met, no matrix will be dis-
played when clicking on the Damage Matrix or Rainflow Matrix icons.

1. You must select an nCode system.

2. The nCode system must be solved.

3. The nCode system must be a Strain or Stress analysis.

If these conditions are not met, a corresponding warning message will be displayed.

Conditions for node Selected: When the nCode system is solved, a fatigue_results.csv file
is generated in the working directory. This file is used to verify the node validity.

• If you select a node that is within fatigue_results.csv file, the software plots the matrix
results corresponding to that node.

• If you select a node that is not within the fatigue_results.csv file, the software finds the
most damaged node within the fatigue_results.csv file and plots the matrix results cor-
responding to that node.

• If you do not select a node (For example if you select a surface, body, or nothing), the software
finds the most damaged node within the fatigue_results.csv file and plots the matrix
results corresponding to that node.

When the conditions are not met and software finds the most damaged node, a message will inform
you that data from the most damaged node is plotted on the matrix.

Solving nCode cycles system: Once you have a solved Stress or Strain system and selected a node,
the nCode analysis runs and returns a cycles_list_1_01.csv file containing the histogram
data that will be represented in the matrix plot.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
66 of ANSYS, Inc. and its subsidiaries and affiliates.
 Performing the Solution

Figure 1.31: Damage Matrix

1.3.8.5. Solid Seam Weld Life and Damage Vector Results

The Damage Vector and Life Vector results are supported for Solid Seam Weld analysis. These
results display of the magnitude and the direction of the Solid Seam Weld life and damage.

The direction of the vector is given by the X, Y and Z Normal weld definition.

Note that the vector graphics display changes to solid vector with uniform size.

1.4. Performing the Solution

This section examines the options for performing a distributed, local or remote machine solution.
1.4.1. Multi-threading
1.4.2. Local Solution
1.4.3. Ansys Remote Solve Manager (RSM)
1.4.4. HPC Platform Services (HPS)

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 67
DesignLife Add-on

1.4.5. Distributed Solve with MPI

1.4.1. Multi-threading
Multi-threading allows a DesignLife analysis to exploit parallel processing and be run on several pro-
cessors simultaneously on a multi-processor or multi-core computer. You can specify the number of
processors to be used by setting the Number of Threads in the Details panel of the Analysis Settings.

The number of threads should be equal to the number of effective processors on the target computer.
This should therefore be set to 2 for a twin-processor, single-core machine, or set to 4 for a twin-
processor machine where each processor is dual-core.

This Analysis Settings option will be written as the NumAnalysisThreads property in the in-
put.dcl file run by dtproc. This is defined as the number of simultaneous analysis threads to use
for this run and is always limited to the number of available thread licenses + 2.

The NumAnalysisThreads property can be overridden at run level by the Librar-

ies/DTLib/DTJob/Run/NumAnalysisThreads DesignLife preference setting. The number of
threads will take this value unless it exceeds the Libraries/DTLib/DTManager/MaxNumAna-
lysisThreads setting, or the number of available licenses.

1.4.2. Local Solution

The My Computer, Background option enables you to solve on your local machine with the ability
to close the Workbench session. This option prompts you to save your project before beginning the
solution process and enables you to close the Mechanical application while the solution completes,
releasing a PrepPost license.

1.4.3. Ansys Remote Solve Manager (RSM)

You can specify the required remote machine using the options on the Solve Process Settings dialog.

The DesignLife add-on can be run through RSM to send the job to another machine, where nCode
must be installed.

Using the RSM configuration, you can define configurations that enable you submit a solve to an es-
tablished compute cluster or cloud portal. This step may be done for you by a person designated as
the RSM administrator to create RSM queues that map to the available HPC queues.

To run on a Linux machine, the following environment variables must be set, where %version%
corresponds to the Ansys numbering version, such as ANSYS232_DIR.

• ANSYS%version%_DIR - pointing to the Ansys installation directory

• ANSYSNCODE%version%_DIR - pointing to the ncode installation directory

• LD_LIBRARY_PATH - the ncode installation directory in must be included in this path

1.4.4. HPC Platform Services (HPS)

You can specify the required remote machine using the options on the Solve Process Settings dialog.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
68 of ANSYS, Inc. and its subsidiaries and affiliates.
 Performing the Solution

The DesignLife add-on can be run through HPS to send the job to another machine, where nCode
must be installed.

HPS enables you to submit solutions and store solver files using multiple, heterogeneous compute
resources. Note that when you have a simulation with linked systems, HPS does not require you to
download the solution data from the upstream systems. Review the sections on Using HPC Platform
Services to Solve Linked Analyses and Understanding HPC Platform Services (HPS) Limitations for
more information.

To run on a Linux machine, the same environment variables as those set in Ansys Remote Solve
Manager (RSM) (p. 68) (above) are required.

1.4.5. Distributed Solve with MPI

A single run of a DesignLife process can be distributed across more than one computer when run as
a batch job. This is done using the MPI (Message Passing Interface) standard. MPI is a widely-used
standard that supports the distribution of applications and facilitates communication between the
components of the distributed application by messaging.

The only part of a DesignLife job that is distributed is that part performed by the analysis engines in
the job configuration. All other aspects, such as FE results file translation, results handling, and post-
processing, are performed on the main machine.

Distributed running has the following characteristics:

• An MPI application has more than one process.

• Each process is allocated a numerical rank from 0 to N-1, where N is the number of processes.

• Each process can be run on an individual computer.

• Multiple processes can be run on a single computer.

• You can choose to simultaneously run multiple processes on one computer, and single processes
on individual computers: MPI is very flexible.

1.4.5.1. MPI Setup

The following configuration must be done on all hosts:

• Install nCode DesignLife on each system.

• Install MPI on the system that runs the distributed application (known as the run time system).
MPI requires a run time system to support the remote invocation of processes and to set
up communication.

– The Intel MPI runtime installer for Windows is included in nCode distributions in the ex-
tras folder. This runtime is not part of the nCode installation but can be installed separ-
ately by running the Intel installer, which is typically named w_mpi-
rt_p_2018.1.156.exe.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 69
DesignLife Add-on

– The runtime must be installed on all the computers that will be used for running the dis-
tributed application. Installing the runtime will install a service which enables start-up of
remote applications. It will also add the runtime binaries folder to the system path.

– Ensure that the MPI application installed is one that is supported by the nCode solver.

• Launch the hydra service and mpiexec register so that credentials are saved:

hydra_service -install

hydra_service -start

mpiexec -register

• Check the firewall permissions and configurations in the DesignLife Documentation and add
the following applications to the firewall:

– From the nCode bin folder allow the dt* executables.

– From the Intel distribution folder allow Mpiexec.exe

To make sure MPI is correctly set up on every host, you can test communications by using
dtdistrib.exe within nCode installation directory.

Note:

Check your MPI setup carefully if the results retrieved are zero when using an MPI
configuration. You can check the configuration is working as expected using the
executable above.

To output log messages, run ncpref from the nCode bin directory and change /Librar-
ies/MPI/LogMessages to All.

1.4.5.2. DesignLife Addon MPI configuration

By default, MPI is not used. If you want to use MPI capabilities, set the Use MPI option within
Analysis Settings to Yes (see below).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
70 of ANSYS, Inc. and its subsidiaries and affiliates.
 Performing the Solution

Figure 1.32: MPI configuration for DesignLife

Set the number of total nodes to use and the Host 2 on which to run the job. The job will be run
using MPI by running the following batch line:

mpiexec -n 1 -host mpihost dtproc_exe dcl_filename -m : -host mpihost2

-n mpinodes dthost2_exe

where:

• mpihost is the machine you are triggering the job from, which will run 1 thread.

• mpihost2 is the machine you are triggering the job to, which by default will be your local
machine.

• mpinodes is the number of nodes that will run on the second machine. This is the total
number of nodes minus 1, as 1 of the nodes is on the main machine.

• dtproc_exe and dthost2_exe are the nCode executables used to run the distributed
jobs, located within the nCode installation directory.

• dcl_filename is the input.dcl that will run.

Each process will use a number of threads equal to the number of cores on the computer it is
running on (as is the case for a non-distributed job run).

The distributed license feature is called DTLib_Distributed, which is in a CDS package named
CAEDistributed. If this license is not available, then the job continues but will not be distributed.
In this case, all nodes are instructed to exit and a message is written to the log (at info level) to
record the reason for not running distributed.

Note that:

• Nodes do not use any licenses except for thread usage.

• Nodes use thread licenses for all threads that they use. There are no "free" threads.

• The main node uses the "free" threads.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 71
DesignLife Add-on

• The working directory should be located on a mapped network drive that is accessible on
both hosts through the same drive letter (for example, Z:\workdir and a shared folder
\\server\SharedFolder have been mapped to Z:\ on both hosts).

1.5. Limitations
The following limitations apply to the Mechanical Embedded DesignLife UI:

• Licensing behavior:

– The DesignLife add-on is Ansys Mechanical Enterprise product family functionality.

The following features in the Mechanical DesignLife add-on are only available with Ansys
nCode DesignLife Premium and Ansys nCode DesignLife Enterprise licenses:

→ Multiple loading events are available. Duty Cycle is available.

→ The Materials Assignment object is available.

→ The Stress Gradients option under Analysis Settings can be set to On.

→ Import and Export loading actions are available.

→ The Gray Iron analysis type is available.

→ The MultiAxial Assessment option can be set to any value.

→ The Elastic Plastic Correction (EPC) option can be set to any value.

→ Safety Factor Analysis is available.

– The UI is only available on the Windows operating system.

– The UI requires an Ansys nCode DesignLife license.

→ If you do not already have the license, contact your Ansys Sales Representative to
obtain one.

→ TECS (Technical enhancements and customer support) is provided under the Ansys
nCode DesignLife Pro license. The Ansys nCode DesignLife Premium and Ansys
nCode DesignLife Enterprise licenses do not provide TECS.

– More than four threads requires an Ansys nCode DesignLife Parallel Add-on license.

– The Shell Seam Weld and Solid Seam Weld analysis types require an Ansys nCode
DesignLife Enterprise license.

• The Mechanical Embedded DesignLife system:

– Should not be connected to a downstream Mechanical system. Only upstream systems

are used in fatigue analysis.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
72 of ANSYS, Inc. and its subsidiaries and affiliates.
 Limitations

– Requires that all upstream systems connected to it are officially supported systems and
all of them are in a solved state.

– Cannot be used as a stand-alone system.

– Only supports temperature-dependent S-N curves and E-N material properties for Fre-
quency Domain analyses with Static Offset.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 73
 Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
74 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 2: NVH Toolkit Add-on
The NVH Toolkit Add-on is conceived to postprocess Noise, Vibration and Harshness results. In addition,
it streamlines FEA-Experimental model comparison calculations of Vibration results, like the Modal As-
surance Criterion (MAC), Coordinate MAC, or Frequency Response Functions (FRFs). It also allows you,
using the XML Converter, to convert load data created by external analysis into a format that can be
readily imported into Mechanical.
2.1. Make the NVH Add-on Available
2.2.The NVH Ribbon
2.3. MAC Calculator
2.4. Stress/Strain Recovery
2.5. FRF Calculator
2.6. Pre-Test Calculator
2.7. EM Loads - XML Converter
2.8. UNV File Restrictions

2.1. Make the NVH Add-on Available

To make the NVH capabilities available, click the NVH Toolkit Icon in the Add-ons Ribbon. The icon
will be highlighted in blue, indicating that the add-on is loaded.

Figure 2.1: Active NVH Icon on the Add-ons Ribbon

Once the add-on is loaded, the NVH Ribbon is visible.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 75
NVH Toolkit Add-on

2.2. The NVH Ribbon

When the NVH Add-on is loaded, the NVH ribbon is accessible. It displays the following buttons:

MAC Calculator (p. 78)

Introduces a result that computes the Modal Assurance Criterion (MAC) between Ansys Mechanical
modal analysis results (rst) and experimental results (unv) or between two different rst results.
It offers several preprocessing/postprocessing capabilities:

• Mode selection and flip

• Mode pairing

• Node selection and position tuning of UNV nodes

• UNV/RST (File 2) model orientation

• Preview Matching Nodes

• Data Interpolation

• Complex to Real Projection

• Filtering Options

• Cyclic Optimization specific workflow

• Interactive MAC Table

• Interactive side-by-side Mode Animation

• Capability of working with On Demand Expansion

Stress/Strain Recovery (p. 99)

Introduces a result that computes the elastic Stress/Strain fields obtained of the linear superposition
of modes according to a Modal Coordinates File (mcf).

FRF Calculator (p. 102)

Introduces a result that computes the Frequency Response Function (FRF) for a given set of input
and output degrees of freedom (DOFs). It offers several preprocessing/postprocessing capabilities:

• Calculate FRF in tailored frequency intervals

• Adjust damping of individual modes

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
76 of ANSYS, Inc. and its subsidiaries and affiliates.
 The NVH Ribbon

• Input/output DOFs rotated to custom reference frame

• Calculate FRF in terms of Compliance (X/F), Mobility (V/F) or Accelerance (A/F) of the input/out-
put DOFs, along with their inverse values for Dynamic Stiffness (F/X), Impedance (F/V) or
Dynamic Mass (F/A)

• Export FRFs to csv and unv format

• Load and review UNV model FRF data, with custom orientation

• Compare computational FRFs or computational and experimental FRFs

• Pair UNV FRFs

Pre-Test Calculator (p. 117)

Introduces a result that identifies optimum sensor and exciter locations for vibration tests. It offers
several preprocessing and postprocessing capabilities:

• Identify optimum sensor locations using the Effective Independence Method (EIM)

• Identify optimum exciter locations using the Driving-Point Frequency Response Function
(DPFRF) method

• Allow custom orientation of both sensors and exciters

• Export the sensor modal results (mode shapes) in unv format

• Export the exciter modal results (mode shapes and DPFRFs) in unv format

• Manual addition of sensors

• Analyze sensor mass effect

• Interactive AutoMAC Table

EM Loads - XML Converter (p. 128)

Introduces a mechanical wizard panel to convert load data from .csv format to .xml format. It
offers the following capabilities:

• Convert single or multiple .csv load files

• Allows radial, tangential and all force components

• Can convert load data available in the time domain to the frequency domain using a Fast
Fourier Transform (FFT)

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 77
NVH Toolkit Add-on

2.3. MAC Calculator

The MAC Calculator introduces a result in the Tree that computes the Modal Assurance Criterion (p. 86)
(MAC) between Ansys Mechanical modal analysis results (rst) and experimental results (unv) or between
two different rst results.

Note:

The MAC Calculator result can only be added under Modal Analyses (Modal, Coupled Field
Modal or Modal Acoustics).

2.3.1. Adding a MAC Calculator result

To Add a Mac Calculator result, you can either:

• Click the MAC Calculator button in the NVH ribbon:

• On the Solution tree object of the Project where the MAC Calculator is to be introduced, click the
right mouse button to open the context menu, then choose Insert → MAC Calculator:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
78 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

When a MAC Calculator result is added, its default properties are populated, and the MAC Frequency
Worksheet pane is located at the left of the Geometry pane, initially empty.

2.3.2. MAC Calculator Details

The following options are available under the MAC Calculator details:
2.3.2.1. File 2 Options
2.3.2.2. MAC Calculation Options
2.3.2.3. Filtering Options
2.3.2.4. Mode Pairing Options
2.3.2.5. Cyclic Optimization Options
2.3.2.6. Optimization Result

2.3.2.1. File 2 Options

File Type

Use the drop-down menu to set the File Type of File 2 to unv or rst.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 79
NVH Toolkit Add-on

Dimension

The model dimension of the rst file, available options are 2D and 3D. Once you have set the
rst file in the File option, this property becomes read-only if your selection and data from the
rst file matches, otherwise you will get an error. Default value is 3D.

Units

The units that quantify the values in the unv file. The default value of Units appears as Dataset
164 (p. 129) in the unv file, which means that the units of the file are input through the units
dataset in the file. The rest of the options are intended for unv files without a units dataset,
and cover common length units (m, cm, mm, ft, in and µm). In addition, you can define a Custom
Length Scale to adjust the dimensions of the unv model with any positive factor. This option
is only available for unv files.

File

Input File 2 using a File dialog. When the file is set, the rest of the File 2 Options are populated,
the MAC Frequency Worksheet is populated, the UNV Node Worksheet appears and the
File 2 geometry is displayed in the Geometry view. If File 2 is a unv file, its format needs to
comply with the restrictions in UNV File Restrictions (p. 129). Contrary to 2023 R2 and earlier
versions, File 2 is not copied to the MAC Calculator subfolder (located in the analysis solver
files directory). This setting holds the absolute path to the file and you may therefore need to
reload the file if renamed, moved to a new location or deleted.

If the File 2 rst file has a defined cyclic symmetry, the results are automatically expanded.

Data Type

If the File Type is set to unv then this property, which contains a list of data type options, is
exposed after loading the file. The options available depend on the Specific Data Type set in
the unv file under Dataset 55 (p. 129). For instance, if the modal data is available for all the
three types, then Displacement, Velocity and Acceleration will appear in the drop-down list.
Whereas, if only one type is available (displacement, velocity or acceleration), then only that
option is selected by default. Note that for MAC calculation purposes, Velocity (V) and Acceler-
ation (A) data from the unv file is converted to Displacement (X) data at each eigenvalue (ω)
using the following expressions, and is compared against displacement data from the rst file.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
80 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

Orient By

Two options are available to orient the rst file relative to the File 1 model, while three options
are available for unv file orientations. Changing any of the options automatically changes the
orientation of the File 2 modelin the Geometry view.

Coordinate System

Supported for both unv and rst files. Orient the unv/rst model according to the RB
transformation defined by the center and rotation of a coordinate system defined in the
model. The selected coordinate system (CS) should be the one that orients the unv/rst
model in the same way that the global coordinate system (GCS) orients the File 1 rst
model.

For example, if node A of the File 1 rst file has coordinates (xA,yA,zA) with respect to the
GCS, the local CS of the unv/rst File 2 file is the one such that the corresponding unv/rst
node to A has coordinates (xA,yA,zA) with respect to the CS.

When Orient By is set to Coordinate System, a Coordinate System property is enabled

to select from the coordinate systems defined in the model.

Rigid Body Transformation

Orient the unv/rst File 2 model according to the RB transformation defined by three
translations (X Translation, Y Translation, Z Translation) and three rotations expressed in the
axis vector-angle representation (Rotation X Axis, Rotation Y Axis, Rotation Z Axis, Rotation
Angle).

The order of the transformations is first Translation, then Rotation. The Rotation Axis does
not need to be normalized.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 81
NVH Toolkit Add-on

3 Node Alignment

Only available for a unv File 2 model. Orient the unv model according to the RB transform-
ation defined by 3 node matches between the rst and unv models. Each Node Pair is
defined through a Tabular Data property that is displayed when the property is clicked.

The rst node can be scoped through either a Named Selection or a Geometry Selection.
In both cases, the selection can only be formed by one node. The Geometry Selection is
directly made by graphically picking in the Geometry pane, whereas the Named Selection
is selected through a drop-down menu.

The unv node is selected through a drop-down menu that displays the unv Node Numbers
as shown in the UNV Node Worksheet (p. 89).

The rst-unv node alignment is produced when you press the Apply button in the property
field.

2.3.2.2. MAC Calculation Options

The MAC Calculator reproduces several RSTMAC command options along with supplementary options
of the MACOPT command in Mechanical APDL. Contrary to release 2023 R1 and previous versions,
it no longer relies on Mechanical APDL commands, but uses Ansys internal operators.

Data Interpolation

Binary property that enables data interpolation. The default value is No, in which case the MAC
Calculator will use the node-matching algorithm. Otherwise, it will use the node-mapping al-
gorithm, which interpolates results based on proximity.

Tolerance

Binary property that enables you to use a tolerance for the node-matching algorithm. It is only
visible if the Data Interpolation (p. ?) option (above) is set to No. The default value is No, in
which case it will always match a node from the second file to a node in the first file, using a
nearest node match algorithm. If Tolerance is set to Yes, it will match nodes that meet the
tolerance requirement specified in Node Matching Absolute Tolerance (p. ?).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
82 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

Node Matching Absolute Tolerance

The absolute tolerance employed in the node-matching algorithm. The default value is 0.01 m.
It is only visible if Data Interpolation (p. ?) is set to No and Tolerance (p. ?) is set to Yes.

Complex to Real Projection

Binary property that allows you to project complex data into the real plane. Default value is
No. This property is visible if modes from either File 1 or File 2 are real and modes coming from
the other file are complex (data must be available). For more information, see Complex to Real
Projection Methodology (p. 94).

Degrees of Freedom

Dropdown property that allows the restriction of the MAC Calculation to a certain subset of
Degrees of Freedom:

All Structural DOFS

No restriction, all available Structural DOFs in the model are employed (UX, UY, UZ, ROTX,
ROTY, ROTZ).

All Translation DOFS

Only the Translation DOFs in the model are employed (UX, UY, UZ).

All Rotation DOFS

Only the Rotation DOFs in the model are employed (ROTX, ROTY, ROTZ).

Custom DOFs

Input the preferred DOFs as a comma-separated string of text.

Export MAC Plot

Binary property that enables the export of the 2D MAC Table in png format after each generation
of the MAC Calculator. When the MAC Table is exported through this option, a mac.png file

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 83
NVH Toolkit Add-on

is saved to the MAC Calculator subfolder, where the rest of the MAC files are saved as described
in MAC Calculator Generation (p. 90).

2.3.2.3. Filtering Options

The following options are available:

Use Filters

Binary property that enables node-filtering options (default = No).

Scoping Method

Allows you to choose between Geometry Selection and Named Selection for the scoping
method.

Geometry Selection

Apply/Cancel property exposed when the Scoping Method is set to Geometry Selection.
Available options are Nodes and Faces, allowing you to select nodes or faces where you
wish to extract nodes.

Named Selection

As above, but exposed when the Scoping Method is set to Named Selection. Available
options are Nodes and Faces.

Use Distance Filter

Binary property that enables filtering based on the distance between nodes (default = No).

Minimum Distance between Nodes

Length property that controls the spatial tolerance used to place sensors and exciters. This
will automatically remove nodes in contact regions and mid-side nodes. Unlike the Pre-
Test Calculator (p. 117), it will not remove nodes on free edges.

Filtered Node Count

Read-only property that displays the count of filtered nodes generated after setting the
Minimum Distance between Nodes option. If you alter the scoped Geometry Selection
or the Minimum Distance between Nodes value, the Filtered Node Count will regenerate
automatically. If you modify the scoped Named Selection, this value will reset to zero and
you will need to revalidate the named selection.

2.3.2.4. Mode Pairing Options

Use these options to enable and customize the automatic mode pairing algorithm (p. 95).

Pair Modes

Boolean option employed to trigger the automatic mode pairing algorithm (p. 95) after the
MAC Table is calculated.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
84 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

MAC Limit

MAC Limit to be employed in the automatic mode pairing algorithm (p. 95).

Frequency Tolerances

The tolerances to be employed in the automatic mode pairing algorithm (p. 95). If Program
Controlled is selected, the default tolerances are employed. They can be further manipulated
employing the User Defined option, that displays the following properties:

RB Modes Cutoff Frequency

Frequency Threshold to filter a Rigid Body Mode

Relative Frequency Tolerance (%)

Relative Tolerance to pair two modes

Absolute Frequency Tolerance

Absolute Tolerance to pair two modes

2.3.2.5. Cyclic Optimization Options

These options are employed to enable a specific workflow useful for models that exhibit cyclic
(cylindrical) symmetry. In these cases, models (rst and rst/unv) can produce bending modes at
random azimuthal angles, and these options are enabled to provide the best possible correlation
between them. This is performed by rotating the second model according to the options below,
and providing the best match of all the possible configurations.

Cyclic Optimization

Boolean option to trigger the Cyclic Optimization workflow.

Cylindrical Coordinate System

If Cyclic Optimization is set to Yes, the cylindrical coordinate system that defines the cylindrical
symmetry of the models.

Optimize By

If Cyclic Optimization is set to Yes, choose either Number of Sectors or Sector Angle, that
are input through the remaining options.

Number of Sectors

If Optimize By is set to Number of Sectors, input the number of sectors that defines the
symmetry of the model.

Sector Angle

If Optimize By is set to Sector Angle, input the sector angle that defines the symmetry of the
model.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 85
NVH Toolkit Add-on

2.3.2.6. Optimization Result

Configure these options to measure the correlation between File 1 and File 2 modes according to
the Objective Function Formulation (p. 96).

Alpha (Frequency Term)

Coefficient of the frequency term in the Objective Function Formulation.

Objective Function (f)

Read-only property, the result of the Objective Function Formulation.

2.3.3. MAC Calculation Method

Note:

For the node matching algorithm, the MAC Calculator will probably not give correct results
for cases where you have several nodes in the same location, as with remote points. This
limitation is related to the fact that this algorithm matches nodes according to location,
so it is not possible to distinguish between them and it will randomly pick one of them.

The modal assurance criterion (MAC) can compare two real solutions or two complex solutions.

The MAC between two real solutions is computed using the equation:

where:

= the ith solution vector of solution 1.

= the jth solution vector of solution 2.

= diagonal of the mass matrix used in obtaining solution k. The MAC between two complex
solutions is computed using the equation:

where:

= the complex conjugate of a complex vector .

In the case of MAC between a real and a complex solution, you can select one of two methods for
the calculation:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
86 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

• Complex to Real Projection (p. ?) property set to No - takes the real part of the complex
solution and uses the Real to Real formulation.

• Complex to Real Projection (p. ?) property set to Yes - takes the Complex to Real Projection
Methodology (p. 94) to convert the complex solution into a real solution, using the Real to
Real formulation.

The modal assurance criterion is not weighted by mass. That is, the mass is assumed to be equal at
all degrees of freedom in cases where:

• The diagonal of the mass matrix is not available, for example with non-structural degrees of
freedom.

• The model is solved with cyclic symmetry.

The dot product of the solution vectors is calculated:

• At matched nodes if the Data Interpolation (p. ?) property is set to No, and at mapped nodes
if it is set to Yes.

• At DOFs selected in the Degrees of Freedom (p. ?) property.

2.3.4. MAC Frequency Worksheet

The first two tables of the MAC Frequency Worksheet are populated with the File 1 and File 2 modes
when File 2 is set. They offer a preview of the available modes in each file. By clicking the right mouse
button after selecting some modes, the following options are available:

Check/Uncheck

If the mode is checked/unchecked, it gets unchecked/checked. This means that this particular
mode is employed/not employed in the subsequent MAC calculations. This option is also triggered
for individual modes if its check box is ticked/unticked.

Move Upwards

The selected modes are moved upwards by one row.

Move Downwards

The selected modes are moved downwards by one row.

Preview

The selected mode is displayed in the Mode Animation View (p. 97).

The Move Upwards and Move Downwards options are especially useful for mode shifts situations
in which two different modes can have very similar frequencies.

The changes that are done in the MAC Frequency Worksheet are instantly translated to the 2D MAC
Table (p. 90).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 87
NVH Toolkit Add-on

After generating data, the Modal Phase Collinearity (p. 96) (MPC) parameter is added for complex
modes.

If you press the Reset Modes button, all modes are ticked and shown in the original order (from
lower frequency to higher frequency).

The third table of the MAC Frequency Worksheet shows the results of the automatic mode pairing
algorithm (p. 95). This algorithm is triggered by either pressing the Pair Modes button at the top of
the worksheet, or by setting the Pair Modes property in the Details View to Yes. When you press
the button, the modes are reordered and paired, and the third table shows the frequency error (ab-
solute and relative) and the MAC values of those mode combinations.

When the modes are paired, two buttons appear at the top of the worksheet that allow you to export
the paired modes results to a CSV file and to visualize the combined mode-pair table.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
88 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

The Preview Matched Nodes option is available as the third button at the top of the worksheet. It
is only visible if the Data Interpolation (p. ?) property is set to No (Matching Node algorithm), data
from File 1 and File 2 is available, but MAC Calculator data has not been generated.

This option allows you to try different configurations of File 1 and File 2 and check if the node
matching is as expected. This data is plotted in the COMAC Table (p. 93).

When the Preview Matched Nodes option is available, every time you change any File 2 Options (p. 79)
or Data Interpolation (p. ?) properties, the data plotted is cleaned.

2.3.5. UNV Node Worksheet

The UNV Node Worksheet is displayed when the unv file is set. It shows the nodes present in the
unv file, with their Node Number and Coordinates (X, Y, Z). It has the following features:

• Selected nodes are highlighted in green in the Geometry pane.

• Coordinates are editable in the Worksheet.

• A check mark in a node's check box indicates that the node will be employed in the subsequent
MAC calculations. Toggle a node's checked status by clicking its check box, or by using the
Show/Hide option on the context menu. Changing the status of any node refreshes the Geometry
pane to display only the checked nodes and hide the unchecked nodes.

• Press the Reset UNV Nodes button above the Worksheet to reset the coordinates to their original
values.

• Press the Show UNV Node Numbers button to display the UNV Node Numbers in labels in the
Geometry view.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 89
NVH Toolkit Add-on

• Manually editing the coordinates should be done after aligning the rst and unv models through
the properties listed under File 2 Options in the MAC Calculator Details (p. 79). If the nodes are
edited and then any option (Coordinate System/RB Transformation/3 Node Alignment) is changed,
the node location is reset.

2.3.6. MAC Calculator Generation

As any other Mechanical result, the MAC Calculator can be generated:

• By solving an Analysis that has an already fully defined MAC Calculator result.

• By right-clicking in the project tree to open the context menu, then choosing Generate.

The generation of the each MAC creates a folder under its Analysis Solver Files directory.

2.3.7. 2D MAC Table

If the MAC Calculator result is successfully generated, a 2D MAC Table pane is shown at the right of
the Geometry pane. The File 1 modes are displayed in rows and the File 2 modes in columns, with
the items of the table showing the MAC values of each pair of modes.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
90 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

Hover in the table to inspect the individual values. Command buttons above the table enable you to
zoom, pan and reset the view of the table.

If the modes in the MAC Frequency Worksheet (p. 87) are checked/unchecked or moved upwards/down-
wards, the 2D MAC Table is automatically refreshed.

Clicking in any item in the table displays the Mode Animation View (p. 97) view.

The 2D MAC Table pane has three buttons:

• Click the first button to Show/Hide the MAC values inside each item in the Table.

• Click the second button to Show/Hide the axis labels.

• Click the third button to Export the MAC Table to png format.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 91
NVH Toolkit Add-on

2.3.8. 3D MAC Table

The 3D MAC Table is generated when a new successful MAC Calculation is produced. It is shown
docked together with the 2D MAC Table (p. 90). The MAC value for each pair of modes is represented
in a bar, defined by its height and color. The modes are displayed in the X and Y directions.

Hover in the Table to inspect the individual values. Command buttons above the table enable you
to switch between the Zoom, Pan and Rotate mode, and to Reset the camera.

If the modes in the MAC Frequency Worksheet (p. 87) are checked/unchecked or moved upwards/down-
wards, the 3D MAC Table is automatically refreshed. In addition, when the Reset Modes or Pair
Modes buttons are clicked in the MAC Frequency Worksheet, the 3D MAC Table is automatically re-
freshed.

The 3D MAC Table pane has one button:

• Click the button to Show/Hide the axis labels.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
92 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

2.3.9. COMAC Table

The COMAC table is produced when a new successful MAC calculation has taken place or when the
Preview Matched Nodes option from the MAC Frequency Worksheet (p. 87) is generated. It is shown
at the same location as the 2D MAC Table (p. 90).

For the Matching Nodes algorithm option (Data Interpolation (p. ?) property set to No) it displays
the list of nodes that have been matched between File 1 and File 2. The selected nodes in the table
are highlighted in magenta (File 1 Node) and green (File 2 Node) in the Geometry pane.

For the Mapping Nodes algorithm option (Data Interpolation (p. ?) property set to Yes) it displays
the list of nodes from File 2, and N/A for all the corresponding nodes of File 1. This happens because
the Mapping Nodes algorithm calculates the node2-equivalent result from the contribution of all
the nodes in File 1, based on their proximity. The selected nodes in the table are highlighted in green
(File 2 Node) in the Geometry pane.

You can also use the COMAC table to compute and display COMAC (p. 94) results. Trigger the calcu-
lation by clicking the button above the table. To produce a successful set of COMAC results, the same
number of modes must be ticked in the MAC Frequency Worksheet (by either having previously run
the Mode Pairing Algorithm (p. 95) or by manually ticking the modes). Calculating the COMAC results
supplements the table with COMAC columns.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 93
NVH Toolkit Add-on

Finally, the information displayed in the COMAC table can be exported to a CSV file when the Export
to CSV button is pressed.

2.3.10. Coordinate Modal Assurance Criterion Calculation

Coordinate Modal Assurance Criterion (COMAC) is an extension to the MAC calculation that identifies
the degrees of freedom that are the source of low correlation between the models. To compute
COMAC, the modes in both models need to be paired. In the MAC Calculator context, this can either
be accomplished using the Automatic Mode Pairing Algorithm (p. 95) or by pairing modes manually
in the MAC Frequency Worksheet (p. 87).

Once the modes have been paired, COMAC is computed as:

Where the following notation is employed:

• COMAC value for degree of freedom (dof ) .

• number of paired modes in both models.

• set of File 1 modes shapes at dof for all paired modes.

• set of File 2 modes shapes at dof for all paired modes.

• complex conjugate of , .

2.3.11. Complex to Real Projection Methodology

Complex to Real Projection is an option available if modes from either File 1 or File 2 are real and
modes coming from the other file are complex. In this situation, complex modes will be converted
to real modes with the following methodology:

• Find the maximum component for complex mode shapes and calculate its phase.

• Rotate all the components of the complex modes by the phase calculated in the previous step,
so that the maximum component is now a pure real component.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
94 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

• Keep the real parts of the rotated components.

The MAC Calculation Method (p. 86) will then use Real to Real formulation.

2.3.12. Automatic Mode Pairing Algorithm

This algorithm provides an indication of possible mode pairs between File 1 and File 2 modes. This
algorithm is triggered:

• By pressing the Pair Modes button in the MAC Frequency Worksheet (p. 87). In this case the al-
gorithm is automatically triggered.

• By setting the Pair Modes property in the project Details to Yes. In this case the algorithm is
triggered after the MAC Calculator (p. 78) is generated.

The algorithm employs the following nomenclature:

• set of modes of File 1.

• set of modes of File 2.

• Rigid Body Modes Cutoff Frequency.

• Absolute Frequency Tolerance.

• Relative Frequency Tolerance.

• MAC value between modes and .

• MAC Limit threshold.

The algorithm is outlined as:

• All modes in both and sets below are unchecked (eliminated).

• All of the surviving modes are ordered in descending order.

• All are not considered for mode pairing.

• All the surviving values are compared (starting from the highest to the lowest), and two
frequency checks are performed:

– Relative frequency check: .

– Absolute frequency check: .

If either the relative or the absolute checks passes, modes and are considered to be paired,
and both of them are blocked to be paired with the subsequent modes.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 95
NVH Toolkit Add-on

The four parameters of the algorithm, , , and can be modified through their respective
properties under the Details (p. 79) view.

2.3.13. Objective Function Formulation

The objective function provides an indicator of the quality of the correlation between File 1 and File 2
modes. It is a minimum objective function, which means that two perfectly well-correlated models
yield an optimum value of 0. The objective function ƒ is computed as:

Where the following nomenclature is employed:

• ƒ Objective Function.

• Weight of the frequency term.

• frequency of the -th File 1 mode in the diagonal of the MAC matrix.

• frequency of the -th File 2 mode in the diagonal of the MAC matrix.

• -th value of the diagonal of the MAC matrix.

If the automatic mode pairing algorithm (p. 95) is set, the modes in the diagonal of the MAC matrix
are the paired modes. If it is not set, the modes that happen to be in the diagonal of the MAC matrix
are the ones employed in the expression.

Therefore, if an optimization/design point analysis is to be conducted, Ansys recommends that the

Pair Modes Property of the MAC Calculator Details (p. 79) view is set to Yes. This will trigger the
automatic mode pairing algorithm before the objective function is computed.

2.3.14. Modal Phase Collinearity

Modal Phase Collinearity (MPC) is a parameter used to quantify the complexity of a mode. It is cal-
culated using the following equation:

where

= the real part of the mode shape

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
96 of ANSYS, Inc. and its subsidiaries and affiliates.
 MAC Calculator

= the imaginary part of the mode shape

This parameter is bounded between 0 and 1, giving a lower value for a more complex mode shape.
A complex-valued mode is only considered if it cannot be converted to a real-valued vector by mul-
tiplication with a scalar. That excludes proportionality between the real and imaginary parts of a mode
shape.

The MPC value is shown in the MAC Frequency Worksheet (p. 87) for complex modes.

2.3.15. Mode Animation View

Display the Mode Animation view below the Geometry pane using either of these methods:

• Choose the Preview option from the context menu in the MAC Frequency Worksheet (p. 87).
This will update the mode in the side (left or right) where you clicked the right mouse button.

• Click any item in the 2D MAC Table (p. 90). It displays the selected pair of modes (The mode
of File 1 in the left, mode of File 1 in the right).

Each graphical window is independent of the other and works with the same controls as the main
Graphical window in the Geometry pane. They have the following controls:

• A Details view with the properties:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 97
NVH Toolkit Add-on

Visualization Options

Only the Relative Scale property is available, employed to rescale the mode displacements.
As MAC is a relative magnitude, this does not affect its value, but only the visualization.

Mode Options

A read-only property that displays the main features of the displayed mode.

For complex modes, there is an option to toggle between Amplitude display or Sweeping
Phase display (0° displays the real component, 90° shows the complex component and any
other angle projects the complex value over the selected phase).

If the Complex to Real Projection (p. 82) option is selected, these options become read-only
properties. The Sweeping Phase value is the value used for sweeping phase of the mode shape.

• A Worksheet view that enables you to show and hide the element types (solid, shell, beam) in
case of rst models and tracelines in case of unv models.

There are four buttons at the bottom of the view that control both graphical windows:

Show/Hide Mesh

For the rst models

Play

Both models are animated

Pause

The animation is paused

Stop

The animation is stopped

2.3.16. MAC Table export

Once the MAC Table is generated, it can be exported by right-clicking the MAC Calculator object in
the tree to open the context menu, and choosing Export to .csv.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
98 of ANSYS, Inc. and its subsidiaries and affiliates.
 Stress/Strain Recovery

2.4. Stress/Strain Recovery

The results recovery feature introduces a result that computes the elastic stress or strain fields obtained
from the linear superposition of modes according to a Modal Coordinates File (MCF).

Note:

The Stress/Strain recovery results can only be added under Modal Analyses (Modal, Coupled
Field Modal or Modal Acoustics).

Note:

The Stress/Strain recovery results require the Vibration Modes from the Modal Analysis to
be the same as the Vibration Modes used to build the Modal Coordinates File. Units may
differ, but the underlying modes must be the same.

2.4.1. Adding a Stress/Strain recovery result

To add a Stress/Strain Recovery result, you can either:

• Press the Results Recovery button in the NVH ribbon and choose Stress Recovery or Strain Re-
covery from the drop-down menu:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 99
NVH Toolkit Add-on

• Right-click Solution in the project tree, then choose Insert → Stress Recovery or Insert → Strain
Recovery:

2.4.2. Stress/Strain Recovery Details

The following options are available under the Stress/Strain Recovery details:

Geometry

Scoping property that enables you to target the recovery process to certain parts/surfaces/edges
or elements/nodes. Both named selections and geometry selections are available.

rst Options

A single property (rst file) enables you to employ a different result file than the one produced
by the Analysis.

The rst file of the Analysis is the default value. The selected rst file should have the same mesh
as the one employed in the analysis.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
100 of ANSYS, Inc. and its subsidiaries and affiliates.
 Stress/Strain Recovery

The stress output (for a Stress Recovery result) or the strain output (for a Strain Recovery result)
should be saved to the rst file to be recovered. This option is enabled by setting Yes in the
appropriate properties under Analysis Settings → Output Controls.

MCF Options

MCF File

Selection of the MCF employed to reconstruct stress and strain. The MCF must be formatted
according to the guidelines in MCF Restrictions (p. 102).

Skip Rows

Integer that controls the number of rows to skip while parsing the MCF.

Normalization

Normalization method employed to produce the Modal Coordinates (Mass Normalization or

Unity Normalization). This property is critical because depending on the normalization method
the dimensions of the Modal Coordinates differ, yielding to different results.

Units

The units of the MCF, in a drop-down list.

Extract Options

By

The Stress/Strain result can be extracted by Time/Time Step (in case of a MCF indexed
by time) or by Frequency/Frequency Step (if the MCF is indexed by Frequency).

For each case a secondary property is displayed (Step Number, Display Time or Display
Frequency). Steps are 1-based, meaning that the first time/frequency step is step #1.

Amplitude and Sweeping Phase

If By is set to Frequency or Frequency Step, the result is complex and therefore it can
be displayed by Amplitude or Sweeping phase.

Stress/Strain Properties

Type

The Type of result that is to be recovered:

• Equivalent (von-Mises) Stress.

• Maximum Principal Stress/Strain.

• Middle Principal Stress/Strain.

• Minimum Principal Stress/Strain.

• Normal Stress/Strain.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 101
NVH Toolkit Add-on

• Shear Stress/Strain.

In case of Normal or Shear Stress/Strain, an additional property is available to choose the

Orientation (X, Y, Z or XY, XZ, YZ, respectively).

Shell Layer

The Shell Layer employed to recover Stress/Strain (Top, Bottom, or Middle). This property
is always displayed by default although it only applies to models with shell elements.
The Top layer is enabled by default.

2.4.3. MCF Restrictions

The MCF should include:

• A header containing any number of lines. The number of lines in the header file is input in
the MCF Options → Skip Rows property (p. 100).

• A space or tab separated list of coordinates, with the first column representing the index
variable (time or frequency) and the rest of the columns being the modal coordinates. If n is
the number of modes:

– If the MCF is indexed by time, modes are real and therefore there should be n+1
columns in total (time column and 1 coordinate per mode and time step).

– If the MCF is indexed by frequency, modes are complex and therefore there should be
(2*n)+1 columns in total (frequency column and 2 coordinates per mode and fre-
quency step, written in its real part and complex part format).

2.5. FRF Calculator

The FRF Calculator introduces a result in the project tree that calculates the Frequency Response
Function (FRF) for a given set of input and output degrees of freedom (DOFs).

Note:

The FRF Calculator result can be added under Modal Analyses (Modal, Coupled Field
Modal or Modal Acoustics). It also can be added under Harmonic Analysis. If Initial
Conditions are defined, mode shapes are read from Modal Analysis. For Standalone

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
102 of ANSYS, Inc. and its subsidiaries and affiliates.
 FRF Calculator

Harmonic Analysis, you must define Solution Method as Mode Superposition and On
Demand Expansion to Yes.

Note:

The FRF Calculator is valid under both Undamped and Damped Modal Analyses. If the
Analysis is Damped, however, the FRF Calculator is only supported with the Reduced
Damped Solver, and the Complex Solutions must be stored.

Note:

The FRAC calculator feature is removed from the current release. The methodology ad-
opted for FRAC calculation in previous releases has some drawbacks as per research
literature. Work on implementing improved methodologies is in progress and this feature
will be available again in a future release.

2.5.1. Adding an FRF Calculator Result

To add an FRF Calculator result, you can either:

• Click the FRF Calculator button in the NVH ribbon:

• Right-click the Solution tree object of the project where the FRF Calculator is to be introduced,
then choose Insert → FRF Calculator:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 103
NVH Toolkit Add-on

2.5.2. FRF Calculator Details

The following options are available under FRF Calculator details:

FRF Definition
Frequency Minimum

The lower bound of the frequency range where the FRF is calculated.

Frequency Maximum

The upper bound of the frequency range where the FRF is calculated.

Frequency Interval

The frequency step used to sample the range between Frequency Maximum and Frequency
Minimum.

Nodes Definition

This property controls the way in which node pairs are introduced in the FRF Worksheet (p. 108).
It can be set to Manual (nodes can only be added directly in the worksheet) or Named Selections
(input and output Nodal Named Selections are input through the Output Nodes and Input Nodes

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
104 of ANSYS, Inc. and its subsidiaries and affiliates.
 FRF Calculator

properties below. In the second case, the worksheet is populated with all possible combinations
of input and output nodes when the two Named Selections are defined.

Output Nodes

The Nodal Named Selection that defines the Output Nodes of the FRF Worksheet (p. 108).

Input Nodes

The Nodal Named Selection that defines the Input Nodes of the FRF Worksheet (p. 108).

UNV Data
Include UNV Data

Binary property used to load/not load UNV Data.

File Type

Read only property automatically set to unv.

Units

The units that quantify the values in the unv file. The default value of Units appears as Dataset
164 (p. 129) in the unv file, which means that the units of the file are input through the units
dataset in the file. The rest of the options are intended for unv files without a units dataset, and
cover common length units (m, cm, mm, ft, in, and μm). In addition, you can define Custom Length
and Force Scales to adjust the dimensions and the FRFs of the unv model with any positive factor.

File

Input File 2 using a File dialog. When the file is set, the rest of the UNV Data are populated. The
format of the unv needs to comply with the restrictions in UNV File Restrictions (p. 129).

Orient By

Three options are available to orient the unv model relative to the File 1 model with a Rigid Body
(RB) transformation. Changing any of the options automatically changes the orientation of the
unv model in the Geometry view.

Coordinate System

Orient the unv model according to the RB transformation defined by the center and rotation
of a coordinate system defined in the model. The selected coordinate system (CS) should be
the one that orients the unv model in the same way that the global coordinate system (GCS)
orients the rst model.

For example, if node A of the rst file has coordinates (xA,yA,zA) with respect to the GCS, the
local CS of the unv file is the one such that the corresponding unv node to A has coordinates
(xA,yA,zA) with respect to the CS.

When Orient By is set to Coordinate System, a Coordinate System property is enabled to

select from the coordinate systems defined in the model.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 105
NVH Toolkit Add-on

Rigid Body Transformation

Orient the unv model according to the RB transformation defined by three translations (X
Translation, Y Translation, Z Translation) and three rotations expressed in the axis vector-
angle representation (Rotation X Axis, Rotation Y Axis, Rotation Z Axis, Rotation Angle).

The order of the transformations is first Translation, then Rotation. The Rotation Axis does not
need to be normalized.

3 Node Alignment

Orient the unv model according to the RB transformation defined by 3 node matches between
the rst and unv models. Each Node Pair is defined through a Tabular Data property that
is displayed when the property is clicked.

The rst node can be scoped through either a Named Selection or a Geometry Selection.
In both cases, the selection can only be formed by one node. The Geometry Selection is
directly made by graphically picking in the Geometry pane, whereas the Named Selection is
selected through a drop-down menu.

The rst-unv node alignment is produced when you press the Apply button in the property
field.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
106 of ANSYS, Inc. and its subsidiaries and affiliates.
 FRF Calculator

2.5.3. FRF Calculation Method

The FRF Calculator employs the residue formulation to estimate the FRF between two given degrees
of freedom (DOFs) using the modal parameters:

where the following notation is used:

• - FRF between the i-th and j-th DOFs, where DOF i is the output and DOF j is the input.

• - Number of modes considered in the FRF calculation.

• - r-th vibration mode, with its real part and its imaginary part:

In terms of the damping coefficient ξr and the undamped frequency , the mode can be
expressed as:

• - residue of the ij DOF pair for mode r. is calculated as:

where is the mass normalized mode shape evaluated at DOF i (a complex magnitude in
general).

• - complex conjugate of x.

can be understood as the output generalized displacement measured in DOF i when an input
generalized force is imposed in DOF j as a function of frequency. Thus, depending on the nature of
the DOFs (whether they are displacement or rotation DOFs), is measured as Displacement/Force,
Rotation/Force, Displacement/Torque or Rotation/Torque.

The analogous relationships between generalized velocity (translational or rotational) and generalized
force, or generalized acceleration (translational or rotational) and generalized force are called Mobility
and Accelerance, respectively.

They are calculated as:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 107
NVH Toolkit Add-on

For a given pair of input and output nodes, a 3x3 FRF matrix can be computed relating the 3 input
and 3 output DOFs measured at each node in the Global Coordinate System (GCS). If that matrix is
denoted as , the FRF matrix expressed in the DOFs along two arbitrary coordinate systems
centered in the input and output nodes is:

where and are the rotation matrices that transform from the GCS to the local output (O) and
input (I) coordinate systems (CS), respectively.

2.5.4. FRF Worksheet

The FRF Worksheet is comprised of 2 or 3 tables depending on the presence of UNV Data.

FRF Frequency Table

The first table in the FRF Worksheet is used to control the modal parameters employed in the FRF
Calculation (p. 107):

The table is populated with the modes from the analysis. If a given mode is selected/cleared, it will
be used/not used in the subsequent FRF Calculation (p. 107). This action can also be triggered by se-
lecting several rows in the table and selecting the Use/Unuse RMB action.

Damping can be tailored for each mode by modifying the value in the damping column. For undamped
analyses, damping is 2% by default for all modes. For damped analyses, damping is automatically
populated according to the value used in the analysis, and it cannot be modified.

Note:

For models that exhibit symmetries that cause mode pairs (for example, models with cyl-
indrical symmetry where bending modes are paired), damping should be changed consist-
ently for all paired modes. This ensures that the symmetry of the model is correctly applied
to the FRF calculation.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
108 of ANSYS, Inc. and its subsidiaries and affiliates.
 FRF Calculator

FRF DOF Pairs Table (Computational Model)

The second table in the worksheet is used to control the DOF pairs to be calculated. The table is initially
empty. There are six RMB actions:

Show/Hide

If the DOF pair is selected/cleared, it is displayed/not displayed in the FRF Plotter (p. 112).
This action supports multi-selection (if several rows are selected, and the Show/Hide action
is selected, all rows are shown/hidden).

Add

Add a new DOF pair to the table. This action does not support multi-selection.

Delete

Delete all the selected rows from the table. This action supports multi-selection (if several
rows are selected, and the Delete action is selected, all rows are removed).

Duplicate

Duplicate all the selected rows from the table. This action supports multi-selection (if several
rows are selected, and the Duplicate action is selected, all rows are duplicated at the end
of the table).

Output Node

Sort worksheet data based on output node IDs. You can toggle between ascending and
descending sort order by clicking the option again. If the Output Node ID is same in any
two or more rows, the data is sorted based on the following order of preference - Input
Node ID, Output DOF and Input DOF.

Input Node

Sort worksheet data based on input node IDs. You can toggle between ascending and des-
cending sort order by clicking the option again. If the Input Node ID is same in any two or
more rows, the data is sorted based on the following order of preference - Output Node ID,
Input DOF and Output DOF.

Each column in the table can be edited in a different way:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 109
NVH Toolkit Add-on

Output Node/Input Node

The contents of these columns are modified through scoping a node from the mesh. If a cell
is clicked, the Geometry view enters Mesh Node selection mode, allowing you to scope
nodes. A set of controls appear at the top of the table allowing you to Apply or Cancel the
selection. Only one node can be scoped. In addition, the input and output nodes can be se-
lected from the Remote Points dropdown menu.

Output DOF/Input DOF

The contents of these columns are modified through a dropdown menu inside the cell that
is populated with all the applicable DOFs for the given node. For the Output DOF, the format
of the selection explicitly indicates Displacement (UX, UY, UZ) and Rotation (ROTX, ROTY,
ROTZ). For the Input DOF, the format of the selection explicitly indicates Force (FX, FY, FZ)
and Torque (MX, MY, MZ).

Output Coordinate System (CS)/Input Coordinate System (CS)

The contents of these columns are modified through dropdown menus inside the cells that
are populated with all the active coordinates systems in the model. By default, the Global
Coordinate System is used. The Output/Input Node IDs and Local Coordinate System triads
are displayed in the Geometry view after changing the CS or Node.

Scalar Load

The contents of this column are modified by entering a scalar value. This value will scale the
output FRF. The column is not available when the Reversed Physics option in the FRF
Plotter is enabled.

Name

The contents of this column are modified by entering text and modifying the predefined
Name. The predefined Name is a mnemonic comprised of the Output and Input DOFs and
Node IDs.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
110 of ANSYS, Inc. and its subsidiaries and affiliates.
 FRF Calculator

Type

Read-only property, containing information about the origin of the FRF.

The second table has four additional actions that can be accessed through the buttons displayed at
the top:

Export Worksheet to Excel

Exports the worksheet contents to an Excel file.

Import Worksheet from Excel

Imports worksheet contents from an Excel file. This Excel file should have the following format:

• The FRF contents should be available in the first sheet of the workbook.

• The file should have 8 columns, starting at cell A1. The columns must be in the same
order as the FRF Worksheet (Output Node, Output DOF, Output CS, Input Node, Input
DOF, Scalar Load, Input CS and Name). Type does not need to be specified.

• Row 1 is reserved for headers.

Expand/Contract Worksheet columns

This option shows/hides the Coordinate System (CS) and Type columns from the FRF work-
sheet.

Open the FRF Comparison Pane

Opens the FRF Comparison Plotter (p. 114).

FRF DOF Pairs Table (UNV Model)

The third table in the worksheet is used to control the FRF pairs contained in the UNV file. It is only
displayed if the Include UNV Data Property is set to Yes in the Details view. The table is automat-
ically populated when the file is parsed, and it has the same structure as the table at the top.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 111
NVH Toolkit Add-on

The FRFs defined in the UNV file cannot be modified, and therefore all columns are read only with
the exception of the Name. This third table supports three RMB actions (Show/Hide, Output Node
and Input Node), which are used in the same way as described for the previous table. When the third
table is displayed, an additional button is shown above the second table to show/hide the UNV Node
Numbers in the Geometry view. The Input and Output CS that define the DOFs employed in the UNV
FRFs are read from the UNV file if Dataset 2420 is available (see UNV File Restrictions (p. 129)), and
imported into Mechanical. These CS are read only and should not be suppressed or eliminated. When
a given Model transformation is performed (either by another CS, by a RB Transformation or by the
Alignment of 3 Nodes), the CS are also changed to match the model update. If the UNV file does not
have any dataset, the generic GCS_unv CS is employed.

2.5.5. FRF Plotter

The FRF Plotter displays the FRF graphs of all the selected DOF pairs (rows) in the second table in
the FRF Worksheet (p. 108). It is displayed when a completely defined DOF pair is selected in a solved
FRF Calculator object.

The FRF Plotter is divided into two parts:

FRF Plot

A dynamic plot that allows hovering, zooming and panning operations. Depending on the
Plot Type, the complex plot can be shown in Magnitude/Phase or in Real/Imaginary graphs.
The maximum and minimum frequency values on the x-axis are restricted to those defined
in the FRF Calculator Details (p. 104). The entire data range can be plotted by clicking the
Autoscale option. Clicking the Home icon (reset axes) replots the data in the user-defined
frequency range.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
112 of ANSYS, Inc. and its subsidiaries and affiliates.
 FRF Calculator

FRF Options

The following properties are available:

• Physics

Allows you to change the Physics of the FRF calculation (Compliance, Mobility or
Accelerance, according to the FRF Calculation Method (p. 107)). You can click the Re-
verse Data button to reverse the physics and instead calculate Dynamic Stiffness
(F/X), Impedance (F/V) or Dynamic Mass (F/A). Reverse Physics will skip 0 values of
the direct FRF.

• Plot Type

Allows you to toggle between the Magnitude and Phase and Real and Imaginary
displays in the FRF Plot.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 113
NVH Toolkit Add-on

An export is triggered by clicking the Export buttons to the right of the Details view.

The file format for export can either be CSV (Export to CSV file button) or UNV (Export to
UNV file button, only if the Physics is not reversed). For CSV files, the FRFs are exported using
the same format in which they are plotted (Magnitude/Phase or Real/Imaginary), and with
the same Physics. For UNV files, the FRFs are exported in Real/Imaginary format and with
Compliance (X/F) Physics.

2.5.6. FRF Comparison Plotter

The FRF Comparison Plotter allows you to display and compare computational and experimental FRFs
or two computational FRFs previously defined and computed in the FRF Worksheet (p. 108). The FRF
Comparison Plotter is opened using the Open the FRF Comparison Calculator button.

The FRF Comparison Plotter is divided into two parts:

FRF Comparison Plot

A dynamic plot that allows hovering, zooming and panning operations. The FRFs are always
displayed in Magnitude and Phase format. The FRF pairs are displayed when a completely
defined FRF pair is selected.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
114 of ANSYS, Inc. and its subsidiaries and affiliates.
 FRF Calculator

FRF Comparison Worksheet

A worksheet with three right-click actions:

Show/Hide

If the DOF pair is selected/cleared, it is displayed/hidden in the FRF Comparison Plot.

This action supports multi-selection (if several rows are selected, the Show/Hide
action is applied to all those rows).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 115
NVH Toolkit Add-on

Add

Add a new FRF pair to the table. This action does not support multi-selection.

Delete

Delete all the selected rows from the table. This action supports multi-selection (if
several rows are selected, the Delete action removes all those rows).

Each column in the worksheet can be edited in a different way:

FRF1

This column defines the first FRF in the FRF Pair. It can be modified through a dropdown
menu that is populated with all the selected FRFs from the computational model (FRFs
from the first FRF DOF Pair Table in the FRF Worksheet (p. 108)).

FRF2

This column defines the second FRF in the FRF Pair. It can be modified through a drop-
down menu that is populated with all the selected FRFs from both the computational
and UNV models (FRFs from the first and second FRF DOF Pair Tables in the FRF Work-
sheet (p. 108)).

Name

The contents of this column are modified by entering text, which changes the predefined
name.

In addition, there are two buttons above the Worksheet with different functionality:

Pair UNV FRFs

This button is only available when UNV data is available. In this case, clicking the
button triggers a 3-step algorithm:

• The nodes that define the selected UNV FRFs in the second DOF Pair Table
are matched with the computational nodes.

• Computational FRFs are defined using the matched nodes and the same DOFs
and coordinate systems. These computational FRFs are the computational
counterparts of the selected experimental FRFs.

• FRF pairs are defined between each experimental and computational FRF
counterpart.

Export to CSV

Exports the contents of the FRF Comparison Worksheet to a CSV file.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
116 of ANSYS, Inc. and its subsidiaries and affiliates.
 Pre-Test Calculator

2.6. Pre-Test Calculator

The Pre-Test Calculator introduces a result in the Tree that identifies the optimum sensor and exciter
locations for vibration tests.

Note:

The Pre-Test Calculator result can only be added under Modal Analyses (Modal, Coupled
Field Modal or Modal Acoustics).

Note:

The Pre-Test Calculator is only valid under Undamped Modal Analyses.

2.6.1. Adding a Pre-Test Calculator Result

To add a Pre-Test Calculator result, you can either:

• Click the Pre-Test Calculator button in the NVH ribbon:

• On the Solution tree object of the Project where the Pre-Test Calculator is to be introduced,
click the right mouse button to open the context menu, then choose Insert > Pre-Test Calcu-
lator:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 117
NVH Toolkit Add-on

2.6.2. Pre-Test Calculator Details

The following options are available under Pre-Test Calculator Details:

Geometry
Scoping Method

Drop-down property, allowing you to choose between Geometry Selection and Named
Selection.

Geometry Selection

Apply/Cancel property available when Scoping Method is set to Geometry Selection. This
property allows you to select nodes, or faces where you want to extract nodes, in order to
obtain the initial candidate set of nodes to filter with the Minimum distance between
sensors property. Available options are Nodes and Faces.

Named Selection

Drop-down property available when Scoping Method is set to Named Selection. This
property allows you to scope a nodal named selection with the initial candidate set of nodes
to filter with the Minimum distance between sensors property. It allows you to select
Named Selections containing nodes or faces.

Definition
Minimum Distance between Nodes

Length property that controls the spatial tolerance employed to place sensors and exciters.
It will automatically remove nodes on free edges, nodes in contact regions and mid-side
nodes. The default value is 2 times the Global Mesh Size.

Filtered Node Count

Read-only property to display the count of filtered nodes generated after adding Minimum
distance between nodes. If you alter the scoped Geometry or Minimum distance between
nodes value, this value will regenerate automatically, but if you modify the scoped Named
Selection, this value will reset to zero and you will need to revalidate the named selection.

Exciter Calculation

Binary property that enables exciter calculation (default = Yes).

Sensor Definition
Proximity between Sensors

Length property that controls the minimum distance between sensors. This offers an addi-
tional filter to place sensors according to the Minimum Distance between Nodes property
(the value selected must be greater than this property). The default value is 4 times the
Global Mesh Size. This property allows you to remove nearby nodes at each iteration of the

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
118 of ANSYS, Inc. and its subsidiaries and affiliates.
 Pre-Test Calculator

EIM, for the top Maximum Number of Sensors EIM nodes. The Maximum number of Sensors
will always take precedence over this property. See Sensor Identification Method (p. 120) for
more information.

Sensor Type

Drop-down property that selects the number of displacement/acceleration degrees of freedom

(DOF) to be measured at each sensor. They can either be Triaxial (3 DOFs per sensor) or
Uniaxial (1 DOF per sensor).

Coordinate System Definition

Drop-down property that controls the way Coordinate Systems are defined at each sensor
location. The Program Controlled option automatically computes a Coordinate System ac-
cording to the Automatic Coordinate System Definition (p. 127).

The User Defined option triggers the presence of the User Defined CS property defined
below. The modification of this property affects all sensors that have already been found and
that are displayed in the Pre-Test Worksheet (p. 124).

User Defined CS

Drop-down property that allows you to scope an existing Coordinate System in the Tree to
define the sensor orientation.

The modification of this property affects all sensors that have already been found and that
are displayed in the Pre-Test Worksheet (p. 124).

Maximum Number of Sensors

Integer property that defines the maximum number of sensors to be found by the Sensor
Identification Method (p. 120). The Maximum Number of Sensors value cannot be higher
than the total number of nodes defined in the Nodal Named Selection scoped in the Named
Selection property.

Respect Maximum Number of Sensors

Binary property that enforces strict implementation of the Maximum Number of Sensors
in the Sensor Identification Method (p. 120).

Exciter Definition
Coordinate System Definition

Drop-down property that controls the way Coordinate Systems are defined at each exciter
location (only available if the Exciter Calculation property is set to Yes). The Program
Controlled option automatically computes a Coordinate System according to the Automatic
Coordinate System Definition (p. 127).

The User Defined option triggers the presence of the User Defined CS property defined
below.

The modification of this property affects all exciters that have already been found and that
are displayed in the Pre-Test Worksheet (p. 124).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 119
NVH Toolkit Add-on

User Defined CS

Drop-down property that allows you to scope an existing Coordinate System in the Tree to
define the exciter orientation (only available if the Exciter Calculation property is set to Yes).

The modification of this property affects all sensors that have already been found and that
are displayed in the Pre-Test Worksheet (p. 124).

2.6.3. Sensor Identification Method

The Pre-Test Calculator employs the Effective Independence Method (EIM) to identify the optimum
location to place sensors. The method is based on the assumption that the optimum location of
sensors is the one that ensures that the measured mode shapes are distinguishable from each other
and provides good signal strength.

The algorithm has the following parameters:

• SN={xn}N – Set of candidate nodes, with NN being its size (the total number of candidate nodes
after filtering).

• Nmax – Maximum number of sensors defined by the user in the Sensor Definition section of
Pre-Test Calculator Details (p. 118).

• {Φi} – Set of modes considered in the analysis. Only the modes that are checked in the Fre-
quency Worksheet inside the Pre-Test Worksheet (p. 124) are employed.

• α – Percentage used to remove nodes after each iteration. This is dependent on the number
of nodes available at each iteration:

– 2.5% if the number of nodes is less than or equal to 1000

– 5% if the number of nodes is greater than 1000 and less than 5000

– 10% if the number of nodes is greater than or equal to 5000

EIM maximizes the Fisher Information Matrix (FIM) determinant, defined as follows:

Where Φxi is the target modal matrix of the ith node. The sensor type affects the size of Φxi and the
method is followed to maximize FIM. The value of x is 1 for uniaxial sensors 3 for triaxial sensors.

• If the sensors are uniaxial, only the displacement degree of freedom in the Z direction of the
Coordinate System defined at the sensor is employed. Thus, the mode shape is first projected
in the local Z direction for each node (reducing from 3N0 to N0 components) and Φxi contains
only one row.

• If the sensors are triaxial, the three displacement DOFs defined at each node are employed in
the calculation, and Φxi contains three rows.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
120 of ANSYS, Inc. and its subsidiaries and affiliates.
 Pre-Test Calculator

The implemented EIM algorithm removes a set of nodes after each iteration until the specified number
of sensors requested by the user is reached. The metric used to assess which sensors are removed is
the determinant of the Fisher Information Matrix. The Effective Independence value corresponding
to the ith sensor is given by:

• If the sensors are uniaxial, E1i is a scalar value that lies in the range [0,1].

Nodes are ranked and sorted in a descending order of E1i. Sensors with a value of this metric
closer to 0.0 contribute less to the determinant of FIM, so they can be deleted.

• If the sensors are triaxial, E3i is a 3x3, fully populated matrix and its metric is calculated as:

Where I3 is a 3-dimensional identity matrix.

Nodes are ranked and sorted in a descending order of E3i. Sensors with a value of this metric
closer to 0.0 contribute less to the determinant of FIM, so they can be deleted.

Sensors remaining after each iteration k are calculated as:

This set of nodes is sorted based on its effective independence value.

Additionally, nodes must comply with the Proximity between Sensors (p. 118) property.

At each iteration, after removing sensors at a rate of α and sorting the nodes based on the E1i or E3i
value, nearby nodes are removed as follows:

The top Nmax nodes with the highest value of E1i or E3i are considered in turn and nearby nodes that
do not meet the Proximity between Sensors property are removed. Removal of nodes stops if the
distance of the remaining sensors reaches the Nmax value.

Iteration continues until the Maximum Number of Sensors value is reached, either at a rate of α or
using the Proximity between Sensors property. If the Respect Maximum Number of Sensors
property in Pre-Test Calculator Details (p. 118) is set to Yes, you will always get the Maximum Number
of Sensors. Otherwise, removal of nearby nodes at the last iteration could result in less than the
Maximum Number of Sensors.

This final set of sensors gives the best configuration for sensor placement, based on the Effective In-
dependence value. It must be noted, however, that these locations offer a degree of manual modific-
ation. If a location offered by the Pre-Test Calculator is inaccessible, it is possible to place the sensor
near to that location instead.

Additionally, an AutoMAC matrix is computed and displayed in the Sensors AutoMAC Panel (p. 122)
for the final set of sensors, Sf.

The AutoMAC matrix is calculated using the following equation:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 121
NVH Toolkit Add-on

2.6.4. Sensors AutoMAC Panel

The Sensors AutoMAC panel offers a visualization tool to interpret modal independence obtained
from the Sensor Identification Method (p. 120). This panel displays an AutoMAC matrix, where the
items of the table show the MAC values for each pair of modes.

The panel has similar functionality to the 2D MAC Table (p. 90) from the MAC Calculator. If the sensors
in the Pre-Test Worksheet (p. 124) are selected/cleared, or if you choose to add sensors manually, the
AutoMAC is updated with the selected sensors (new sensors will be selected by default).

You can hover in the table to inspect individual values. Command buttons above the table allow you
to zoom, pan and reset the view of the table.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
122 of ANSYS, Inc. and its subsidiaries and affiliates.
 Pre-Test Calculator

The Sensors AutoMAC table panel has two buttons:

• Click the first button to show/hide the MAC values inside each item in the table.

• Click the second button to export the MAC table to png format.

2.6.5. Exciter Identification Method

The Pre-Test Calculator employs the Driving-Point Frequency Response Function (DPFRF) method to
identify the optimum location to place exciters. The method is based on the assumption that the
optimum location of exciters is the one that ensures higher peaks in its Driving Point FRF, and it
therefore enhances the resonance of the structure.

The algorithm has the following parameters:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 123
NVH Toolkit Add-on

• SN={xn}N – Set of candidate nodes (the total number of candidate nodes after filtering).

• {Φi} – Set of modes considered in the analysis. Only the modes that are checked in the Frequency
Worksheet inside the Pre-Test Worksheet (p. 124) are employed.

• NE – Maximum number of exciters.

For each node in SN, the method consists of computing the peaks of the Accelerance DPFRF in the
local Z direction. That is, to project the displacement degree of freedom in the Z direction determined
by the local coordinate system at the candidate node and to compute its Accelerance DPFRF. This
FRF is computed with the same methodology described in FRF Calculation Method (p. 107).

Particularizing for the case of real mode shapes with equal input and output DOFs, and taking into
account that the peaks of the Accelerance DPFRF are approximately located at the modal frequencies,
the peaks of the DPFRF for each node n are:

The modal damping ratio that is assumed for all modes is 2%.

Once all peaks are computed (for each candidate sensor, a peak is computed per normal mode ),
a metric is computed for each candidate node. This metric consists of calculating the maximum of
the DPFRF peaks. This is an indicator of the maximum strength of the response:

Finally, the candidate nodes are sorted according to this metric and the first NE nodes are considered
the best exciters.

2.6.6. Pre-Test Worksheet

The first table in the Pre-Test Worksheet is used to control the modes used in the Pre-Test Calculat-
or (p. 117):

The table is populated with the modes from the analysis. If a given mode is selected/cleared, it will
be used/ignored in the subsequent Sensor (p. 120) and Exciter (p. 123) Identification. This action can
also be triggered by selecting several rows in the table and applying the Use/Unuse right-click action.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
124 of ANSYS, Inc. and its subsidiaries and affiliates.
 Pre-Test Calculator

The second and third tables in the worksheet are used to control the local Coordinate System at each
sensor and exciter location. Both tables are initially empty and have the following right-click actions:

Show/Hide

If a sensor or exciter is selected/cleared, it is displayed/hidden in the Geometry view. This

action supports multi-selection (if several rows are selected, the Show/Hide action is applied
to all selected rows). Additionally, the AutoMAC Table is updated dynamically, considering
only sensors selected in the second table.

Add

This action is only available for the second table (Sensors Table). It allows you to add sensors
to the analysis after selecting nodes in the Geometry view (only selection of nodes is allowed).
The AutoMAC Table is also updated once this action is completed.

You can also add sensors before the analysis.

In the Sensors Table, the Method used to find the sensor is shown in the last column.

In addition to the tables, there is a Details view at the top of the third table that has the following
properties:

Number of Exciters

Integer property that changes the number of exciters that are considered. Changing this
value triggers a dynamic update of the Pre-Test Worksheet plot.

Exciter and Sensor Icon Scale Factor

Scale factor property that controls the size of exciter and sensor icons (arrows and spheres).

Each column in the table contains the following information:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 125
NVH Toolkit Add-on

CS Definition

Similar to the Coordinate System Definition Properties (p. 118) for sensor and exciter definition,
this property allows you to switch between Program Controlled and User-Defined, and in
this case it only affects the individual sensor or exciter that is modified.

User Defined CS

Similar to the User Defined CS Properties (p. 118) for sensor and exciter definition, this property
allows you to scope a previously defined Coordinate System to an individual sensor or exciter.
It is only available if the CS Definition at the given row is scoped to User Defined.

Ranking

Read-only column that shows the order of the sensors/exciters according to their algorithm
(EIM/MDPFRF). Sensors and exciters in the table are sorted based on this value.

The Sensor table has one additional column:

Method

Read-only column that indicates the method used for sensor selection. EIM stands for Effective
Independence Method, while Manual refers to the user-defined sensors.

The Exciter table also has one additional column:

MDPFRF

Read-only column that indicates the value of the Maximum Driving Point Frequency Response
Function, calculated according to the Exciter Identification Method (p. 123).

The second and third tables have four additional actions that can be accessed through the buttons
displayed at the top:

Display sensor/exciter IDs

Shows the sensor/exciter IDs in the Geometry view, allowing for easier identification.

Analyze Sensor Mass Effect

Click this button to start the Sensor Mass Effect Analysis (p. 127) workflow.

Create Named Selections for Sensors and Exciters

Allows the creation of a Named Selection for selected sensors and exciters.

Export to UNV file

Allows the export of selected sensor and exciter information in unv format after each gener-
ation of the Pre-Test Calculator. _sensors and _exciters suffixes are added to the chosen
filename.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
126 of ANSYS, Inc. and its subsidiaries and affiliates.
 Pre-Test Calculator

2.6.7. Sensor Mass Effect Analysis

The objective of this feature is to analyze the effect that the addition of the sensors has on the
modal properties of the structure (modification of the mode shapes and reduction of the eigenfre-
quencies). You can enable the workflow by enabling the binary Analyze sensor mass effect property
in the Pre-Test Calculator Details (p. 118).

The Modal Analysis that holds the Pre-Test Calculator is then duplicated, and a Sensor Mass load
object is added to the Tree. The load has the following properties:

Definition Method

Drop-down property that allows you to select either Constant or Defined by Worksheet
mass definition. If Constant is selected, the same mass value is used for all sensors, and it
can be introduced in the Sensor Mass property below. If Defined by Worksheet is selected,
the mass of each individual sensor can be introduced in the Sensor Mass Worksheet.

Sensor Mass

Sensor Mass, when Constant is selected as the mass Definition Method.

When the Analysis is then solved, the mass at each sensor is added to the Finite Element
formulation as an attached Point Mass.

2.6.8. Automatic Coordinate System Definition

Automatic Coordinate Systems are computed at each sensor/exciter location so that their local Z
direction is oriented towards the exterior normal to the surface, with the X and Y directions defining

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 127
NVH Toolkit Add-on

the tangent plane. This is accomplished by finding the unique rotation without drill that maps the Z
axis of the Global Coordinate System (denoted as ) to the normal vector at the sensor/exciter (de-
noted as ).

Mathematically:

with representing the vector product matrix of vector .

2.7. EM Loads - XML Converter

The EM Loads - XML Converter wizard is used to convert electromagnetics (EM) load data created by
an external analysis (such as Maxwell) from .csv format to .xml format. The resulting .xml file can
then be imported to Mechanical using Imported Remote Loads.

2.7.1. Launching the XML Converter Wizard

To launch the wizard, you can either:

• Click the EM Loads - XML Converter button in the NVH Toolkit ribbon.

• Select the Automation tab, select Open Wizard and then select EM Loads - XML Converter
Wizard in the Wizard panel.

2.7.2. Using the XML Converter Wizard

The following options are available in the XML Converter wizard:

Input Data (CSV Data)

Add input data and set the following properties:

• Input File: select the load data available in .csv format. This load data is generally
created by an external analysis, such as Maxwell. Both time domain and frequency
domain load data is supported. If the data is in the time domain, a Fast Fourier
Transformation (FFT) is applied to convert it to frequency domain.

• Convert Files: options are Selected File (default) and All Files in Folder. With the
default option, only the selected file will be used for conversion. For All Files in Folder,

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
128 of ANSYS, Inc. and its subsidiaries and affiliates.
 UNV File Restrictions

all the .csv files present in that folder will be used to generate a combined load file
in .xml format.

• Force Component: options are All Components (default), Radial and Tangential.

Ouput Data (XML Data)

Set properties for the output .xml file.

• Output File Name: options are Program Controlled (default) and User-defined. With
Program Controlled, the name of the .xml file is same as that of the selected .csv
file, whereas a user-defined name can be entered in case of the latter.

Generate XML

After selecting all the required inputs and setting properties, click the Generate XML button
to generate the load file in .xml format. This file is created in the same location as the input
.csv file. The resulting .xml file is compatible with the format supported by the Imported
Remote Loads object.

2.7.3. Closing the XML Converter Wizard

Upon completion, click Exit Wizard to close the dialog. Then click the Open Wizard toggle button
(under Automation) or the Close button on the Wizard panel to close the panel.

2.8. UNV File Restrictions

The unv file must be formatted according to the standard developed by the SDRC in the 60s-70s that
is outlined at the University of Cincinnati – Structural Dynamics Research Laboratory (UC-SDRL) site.

The unv file is structured in datasets split by -1 symbols that can appear in any order.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 129
NVH Toolkit Add-on

The following datasets are mandatory for both MAC (p. 78) and FRF (p. 102) Calculators. If they are not
found in the unv file the MAC Calculator will not work:

• Either Dataset 15 or 2411 (Node coordinates), but not both in the same unv file.

The following dataset is mandatory for the MAC Calculator (p. 78):

• Dataset 55 (Modal Parameters). The following options are supported:

– Model Type (record 6, field 1):

→ Structural: 1

– Analysis Type (record 6, field 2):

→ Normal Modes: 2

→ Complex Modes: 3

– Data Characteristic (record 6, field 3):

→ 3 DOF Global Translation Vector: 2

→ 6 DOF Global Translation and Rotation Vector: 3

– Specific Data Type (record 6, field 4):

→ Displacement: 8

→ Velocity: 11

→ Acceleration: 12

– Data Type (record 6, field 5):

→ Real: 2

→ Complex: 5

The following dataset is mandatory for the FRF Calculator (p. 102):

• Dataset 58 (Function at Nodal DOF). The following options are supported:

– DOF Identification (record 6, field 1):

→ Frequency Response Function: 4

– Load Case Identification Number (record 6, field 4):

→ Single Point Excitation: 0

– Response (Output) Node and Reference (Input) Node (record 6, fields 6 and 9):

→ Any node number defined in the compulsory node coordinates dataset.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
130 of ANSYS, Inc. and its subsidiaries and affiliates.
 UNV File Restrictions

– Response (Output) Direction and Reference (Input) Direction (record 6, fields 7 and 10):

→ +X Translation: 1

→ -X Translation: -1

→ +Y Translation: 2

→ -Y Translation: -2

→ +Z Translation: 3

→ -Z Translation: -3

→ +X Rotation: 4

→ -X Rotation: -4

→ +Y Rotation: 5

→ -Y Rotation: -5

→ +Z Rotation: 6

→ -Z Rotation: -6

– Ordinate Data Type (record 7, field 1):

→ Real, single precision: 2

→ Real, double precision: 4

→ Complex, single precision: 5

→ Complex, double precision: 6

– Abscissa spacing (record 7, field 3):

→ Uneven: 0

→ Even: 1

– Abscissa Data Characteristics (record 8, field 1):

→ Frequency: 18

→ Rpm: 19

– Ordinate Numerator (Output) Data Characteristics (record 9, field 1):

→ Displacement: 8

→ Velocity: 11

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 131
NVH Toolkit Add-on

→ Acceleration: 12

– Ordinate Denominator (Input) Data Characteristics (record 10, field 1):

→ Excitation Force: 13

The following datasets are optional. If they exist in the model, the MAC (p. 78) or FRF (p. 102) Calculators
use them, and if they do not exist the default workaround applies:

• Dataset 164 (Units). If Dataset 164 is present, the Units property under File 2 Options (p. 79) in
the MAC Calculator (p. 78) or under UNV Data (p. 102) in the FRF Calculator (p. 102) should be scoped
to Dataset 164 (unv file). If it is not present, the Units property should be scoped to the applicable
length unit of the file.

• Either Dataset 2420 or Dataset 18 (Coordinate Systems). If neither is present, all Modal parameters
are assumed to be expressed in the Global Coordinate System.

• Dataset 82 (Tracelines). This dataset is only employed to display the unv model.

• Dataset 2412 (Mesh). This dataset is only employed to display the unv model. Only the display of
linear 1D, 2D and 3D elements (beams, tris, quads, tets and hexas) is supported.

If neither Dataset 82 nor 2412 are present in the unv file, the unv model is displayed as a point
cloud in the Geometry pane.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
132 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 3: Forced Response Add-on
The Forced Response Add-on provides a comprehensive way of investigating the aeromechanics, and
ultimately, the reliability of turbomachinery blade rows. Working in conjunction with Ansys Computa-
tional Fluid Dynamics (CFD) tools, the Forced Response Add-on accurately predicts the structural vibra-
tions of industrial components. Advanced physical phenomena such as airfoil aeroelasticity, flutter, de-
terministic and probabilistic mistuning, as well as an array of loading and boundary conditions can be
modeled and studied. Efficient high-fidelity modeling is achieved using a combination of core techno-
logies such as cyclic symmetry and mode-superposition as well as innovative techniques to model
mistuning and aeroelasticity in a reduced space. Based in Workbench Mechanical, the Forced Response
Add-on is the most intuitive, reliable, and efficient way to simulate turbomachinery blade rows.
3.1. Introduction to Forced Response
3.2. Make the Forced Response Add-on Available
3.3. Setting Up the Forced Response Analysis
3.4. Multistage Harmonic Choice Wizard
3.5. Multiharmonic Combination
3.6. Post-processing
3.7.Troubleshooting

3.1. Introduction to Forced Response

The Forced Response application is an add-on to the Ansys Mechanical user interface that enables you
to use cyclic modeling. A cyclic symmetry analysis requires that you model a single sector, called the
base sector. A proper base sector represents one part of a pattern that, if repeated n times in cylindrical
coordinate space, yields the complete model, as shown:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 133
Forced Response Add-on

Forced Response Analysis:

• Determines the blade response (motion & stresses) due to excitation from neighboring blade rows

• The excitation happens at multiples of the rotation frequency of the rotor

• Resonance crossing between excitation (EO line) and mode frequency must be identified and forced
response estimation is performed

• Forced response yields blade fatigue data that can be used for blade life analysis

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
134 of ANSYS, Inc. and its subsidiaries and affiliates.
 Introduction to Forced Response

Forced Response of Cyclic Symmetric Model

• Cyclic Mode Superposition (MSUP) Harmonic

• Tuned: All blades are assumed identical, and are modeled on single blade

Workflow

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 135
Forced Response Add-on

Small Stiffness Mistuning in Cyclic MSUP Analysis

In Cyclic Mode Superposition (MSUP) Harmonic analysis:

• Mistuned object takes tuned response and adds the mistuning effects of each blade in cyclic
analysis

• Small mistuning — variation of in blade stiffness should not be more than 10%

Note:

The Forced Response Add-on is only available on the Windows operating system. Its use re-
quires an Ansys Mechanical Premium or Ansys Mechanical Enterprise license. If you do not
already have the license, contact your Ansys sales representative to obtain one.

3.2. Make the Forced Response Add-on Available

To make the Forced Response capabilities available, click the Forced Response icon in the Turboma-
chinery subsection of the Add-ons Ribbon. The icon will be highlighted in blue, indicating that the
Add-on is loaded.

Figure 3.1: Active Forced Response Icon on the Add-ons Ribbon

When the Forced Response Add-on is loaded, the Forced Response ribbon is accessible. It displays the
following buttons:

3.3. Setting Up the Forced Response Analysis

To perform a Forced Response analysis, connect a Static Structural with a Modal analysis in Workbench.
Then insert a connected Harmonic system.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
136 of ANSYS, Inc. and its subsidiaries and affiliates.
 Setting Up the Forced Response Analysis

3.3.1. Setting Up the Static Structural Analysis

In the Static Structural analysis, create a Forced Response Pressure Map load object.

Creating the Forced Response Pressure Map object in the Static Structural analysis enables the use
of Aerocoupling in the Harmonic Response system.

3.3.2. Setting Up the Modal Analysis

The Modal Analysis must be pre-stressed with the Static Structural system. In the Analysis Settings of
the Modal system, the Future Analysis field under Analysis Data Management must be set to MSUP
Analyses. To activate the Cyclic Mode Superposition option, turn on the Beta flag by selecting Yes
in the Cyclic Mode Superposition field.

Note:

Most Forced Response results require generated files. Set the Delete Unneeded Files option
to No. This option is under Analysis Data Management in the Analysis Settings of the
Modal system.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 137
Forced Response Add-on

Leave the Solver Type within the Solver Controls set to Program Controlled. Only Block Lanczos
is supported. For more information, see Mode-Superposition Harmonic Cyclic Symmetry Analysis.

Note:

For Mistuning and Aerocoupling, the files with the extensions .rstp, .r001, .rdb, and
.ldhi are required. In the Modal Analysis settings, the Delete Unneeded Files field must
be set to No to ensure these files are present.

Alternatively, add a post command in the Solution of the Modal to copy over the files, as
follows:

/post1 ! Enter /SOLU module

! Copy the RSTP file to file.rst in user files (RSTP is the results file extension after Linear perturbation
/COPY,file.rst,,,%_wb_userfiles_dir(1)%file.rstp
file,,rst ! Open file.rst in APDL
/show,png,rev ! Save plots in in png format from APDL
/yrange,0,3000, ! Set the Y range for the next plotting to 0-3000 Hz.
plzz,16043 ! Plots the speed lines (16043 RPM) in interference diagram
/show,close
fini
/COPY,file.r001,,,%_wb_userfiles_dir(1)%file.r001
/COPY,file.rdb,,,%_wb_userfiles_dir(1)%file.rdb
/COPY,file.ldhi,,,%_wb_userfiles_dir(1)%file.ldhi

3.3.3. Setting Up the Harmonic Analysis

The Harmonic Analysis must be pre-stressed with the Static Structural system and have the Modal
Environment selected.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
138 of ANSYS, Inc. and its subsidiaries and affiliates.
 Setting Up the Forced Response Analysis

The Solution Method field must be set to Mode Superposition. To activate the Cyclic Mode Super-
position option, turn on the Beta flag by selecting Yes in the Cyclic Mode Superposition field.

Note:

Most Forced Response results require generated files. Set the Delete Unneeded Files option
to No. This option is under Analysis Data Management in the Analysis Settings of the
Harmonic system.

Leave the Solver Type within the Solver Controls set to Program Controlled. Only Block Lanczos
is supported. For more information, see Mode-Superposition Harmonic Cyclic Symmetry Analysis.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 139
Forced Response Add-on

3.3.4. Setting Up the Interference Diagram

Interference Diagram plots the cyclic modal frequencies versus the harmonic index data as red
rhombuses. The speed lines are also superimposed on the diagram for each speed multiplier. This is
also known as a SAFE or ZZENF diagram and indicates potential frequencies where resonance may
occur.

Note:

Interference Diagram does not always guarantee the true resonance. It suggests that res-
onance occurs whenever the natural frequency of the block matches the excitation fre-
quency. However, due to the cyclic nature of the structure, the mode shape may not match
the Engine Order excitation shape coming out of the nozzles for the diagram's suggested
critical speed. Hence, the SAFE or Interference Diagram, which relates the mode shapes
with speed and natural frequency, predicts the true resonance and is used by industries
for reliable design.

The Rotational Speed field is auto-populated from the Rotational Velocity value of the Static Struc-
tural system pre-stressing the Modal system and can be edited.

One or several engine orders may be plotted by setting values separated with commas (',).

Note:

Only positive values are accepted.

The figure below illustrates an Interference Diagram with three speed lines. The speed lines follow
this formula:
(3.1)

where corresponds to the frequency, to the harmonic index, and to the rotational velocity.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
140 of ANSYS, Inc. and its subsidiaries and affiliates.
 Setting Up the Forced Response Analysis

Figure 3.2: Interference Diagram with Three Speed Lines

3.3.5. Mistuning Settings

Mistuning on Cyclically Symmetric Structures

Small mistuning effects (on the order of a few percent) may be included in the analysis by introducing
blade-to-blade variations in the stiffness (frequency) of each blade.

Mistuning is based on the Component Mode Mistuning methodology (see Mistuning in the Mechan-
ical APDL Theory Reference), which requires the elements making up the blade and the interface
nodes between these elements and the rest of the sector model to be in an element and nodal

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 141
Forced Response Add-on

component (CM) respectively. Use the CYCFREQ,BLADE command option to provide this information,
as well as how many blade modes to include and their frequency range.

For blades with shrouds, the nodes on the shroud boundaries should also be in the node component
(if the shroud interfaces are modeled as stuck).

The mistuning parameters are provided in a parameter array of size Ν×1, where Ν is the number of
blades. Each row represents the deviation in stiffness of each blade δn from the nominal value [Κ0]
used in the modal cyclic symmetry analysis. Equivalently, the stiffness deviation, , may

be expressed in terms of each blade's natural frequency deviation squared, , where ω is the
n
nominal (tuned) blade frequency and ω is the mistuned frequency of blade n.

It should be noted that the stiffness deviation is equivalent to where [Ε]

denotes the Young's modulus only in the case where there are no prestress effects. In the presence
of prestress, the nominal stiffness [Κ0] is updated, and then mistuning is applied.

You may also mistune each of the individual blade frequencies, in which case the provided array
parameter would be Ν×Μ, where each column is for the Μ blade frequencies (from the CYC-
FREQ,BLADE specification), and each entry corresponds to that blade's frequency deviation squared,
, where the subscript ι refers to the ιth frequency of blade n (such that the array location
(n,ι) contains this value).

Use the CYCFREQ,MIST command to provide this array name.

Mistuning Load Definition

Pick the blade and blade interface. If shared topology is used, the blade interface should be selected
automatically.

• The number of blade modes to include in the CMS reduction. Refers to the Mechanical APDL
command CYCFREQ,BLADE,,,value.

• The number of sectors is automatically populated and gives the number of mistuning values
to be input.

• Mistuning can be entered manually, imported from a .csv file, or be randomly generated.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
142 of ANSYS, Inc. and its subsidiaries and affiliates.
 Setting Up the Forced Response Analysis

File

Select a .csv file. This file must contain a set of mistuning parameters per column. The
Column in Mistuning Parameter File setting defines which columns will be read in the
file. Using that setting, you can parameterize the mistuning parameter for each blade. The
number of rows in the file must be equal to the number of sectors.

Random

Choose between Normal (Gaussian) or Uniform distribution. A new set of random mistuning
values will be generated every time the Random Mistuning Parameter Set value is
changed. You can perform several analyses using the same random mistuning value. The
random mistuning values are saved for later review.

Understanding Changes to ds.dat

Including the mistuning load modifies the ds.dat file of the Harmonic system accordingly to include
the mistuning definition.

• The blade elements and interference nodes are defined according to the scoped geometry.

• *DIM,KMIST,ARRAY,BM,1 is included, where BM is the number of sectors defined.

• KMIST defines the mistuning parameters for each blade.

• CYCFREQ,BLADE,ACTInterfaceNodes,ACTBladeElem,BN defines blade element component and in-

terface nodes, where BN is the number of cantilever beam shapes.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 143
Forced Response Add-on

• CYCFREQ,MIST,K,KMIST defines stiffness mistuning.

3.3.6. AeroCoupling Settings

Aerocoupling on Cyclically Symmetric Structures

Aerodynamic coupling effects can be included in the Forced Response analysis. Aerodynamic coeffi-
cients account for vibration-induced pressure fluctuations on the blade surface, and contribute to
the stiffness and damping of the system. These values can be computed according to the equations
for Aerodynamic Coupling in the Mechanical APDL Theory Reference and are included in the cyclic
mode-superposition harmonic response using the CYCFREQ,AERO command. The aerodynamic
coefficients can be computed directly using a CFD flutter or aero damping analysis. The aerodynamic
coupling coefficients can also be computed using CFD pressures in conjunction with the AEROCOEFF
command. For more details on computing and including aerodynamic coefficients, see Aero Coupling.

Aerocoupling Load Definition

The aerocoupling or aerodamping can be included if the coupling files have been generated using
cfx.

1. The Reference Coordinate System of the AeroCoupling objects must be selected so that the
Source Points are aligned with the Geometry. You can check if they are aligned by switching the
Display Source Points to Yes. If the Source Points are displayed correctly, that means the Coordin-
ate System definition is correct.

2. Select the faces on which the pressure is applied. By default the same faces and coordinates as
the ones selected for Force Response Pressure Map will be selected. You might also use the
Seek function after selecting the files.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
144 of ANSYS, Inc. and its subsidiaries and affiliates.
 Multistage Harmonic Choice Wizard

3. Browse for a folder containing all the aerodamping files, or enter each file using the Tabular Data
tool

4. Check Tabular Data to make sure that the nodal diameters are associated with the correct file.
To better understand the concept of nodal diameter refer to Modal Cyclic Symmetry Analysis.

5. The aero scaling and nodal diameter will be read from the files and may be modified.

6. If no mistuning is present (or if mistuning is suppressed), the blade, blade interface, and number
of cantilever mode shapes must be defined. If mistuning is created afterwards or unsuppressed,
select the aerocoupling object in the tree again to remove the selection.

7. Right-click the AeroCoupling object, and choose Generate to generate the aerodamping coeffi-
cients.

8. The aerodamping coefficients for each blade will be displayed.

9. If you press Solve before generating the aerodamping, the coefficient will be calculated before
solving.

Understanding Changes to ds.dat

• The blade elements and interferences nodes are defined according to the scoped geometry or the
defined mistuning object.

• /COM AEROCOEFF command computes the aero-damping and stiffness coefficients, and writes
them to an APDL array.

• PARRES,CHANGE,AeroParm,PARM

• *STAT,FileAeroArray

• CYCFREQ,AERO,FileAeroArray specifies the array containing the aerodynamic damping coefficients.

3.4. Multistage Harmonic Choice Wizard

The Multistage Harmonic Choice Wizard is a valuable tool for accurately simulating cyclically symmetric
systems with multiharmonic phenomena using the multistage analysis procedure. Multistage displacement
solutions are the sum of contributions of many harmonic functions, only some of which significantly
affect the response. This wizard helps you determine which harmonic indices (HIs) should be included
in each stage for an accurate response, a useful tool as:

• Including multiple HIs can improve accuracy for models with multiharmonic phenomenon

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 145
Forced Response Add-on

• Including all harmonics in each stage increases the time and computational effort enough to
defeat the purpose of multistage modeling

• Randomly choosing harmonic indices may lead to a solver error if the chosen HIs are uncoupled,
resulting in no constraint equations generated between stages

The Multistage Harmonic Choice Wizard calculates and lists which harmonic indices (HIs) are relevant
at each stage by evaluating the relationship between the nodal diameters and HIs. For an example
problem demonstrating this and detailing the underlying equations, see Static Analysis of a 2-Stage
Disk with Pinholes. For a discussion on the concepts of harmonic index and nodal diameters of a cyclically
symmetric structure and their relationship, see Understanding Harmonic Index and Nodal Diameters in
the Cyclic Symmetry Analysis Guide.

Note:

The wizard is only available for models that include a Stage object with a defined cyclic
symmetry region (either a Cyclic Region or Pre-Meshed Cyclic Region object).

Figure 3.3: Calculate Indices Dialog in Multistage Harmonic Choice Wizard

Specify these values in the Wizard dialog in the following order, as shown in the image above:

1. Inputs Fields for the Wizard

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
146 of ANSYS, Inc. and its subsidiaries and affiliates.
 Multistage Harmonic Choice Wizard

• Main Harmonic: Specify the main harmonic index for the response, which depends on the engine
order (excitation) of interest. It must be an integer greater than or equal to zero. The maximum
available value is the lowest maximum harmonic index of all stages.

• Consider Only Adjacent Stages: Select Yes to use the interstage connections that are defined
in your model (via Interstage objects) in the calculation of relevant harmonic indices. If it is set
to No, the algorithm considers all possible combinations of two stages, regardless of the interstage
connections defined in the model.

• HI Coupling Method: Select the method used to compute the coupled harmonic indices among
the following 3 options (from the minimum to maximum number of coupled harmonic indices):

– Fundamental Nodal Diameters: The wizard only calculates the aliased harmonic indices
coupled with the main harmonic.

– First Extension of Fundamental Nodal Diameters: The wizard extends the previous
concept to include higher nodal diameters up to the Maximum Nodal Diameter specified
for the main harmonic only.

– All Nodal Diameters: The wizard computes all coupled harmonic indices below the Max-
imum Nodal Diameter specified without restrictions on the main harmonic.

• Maximum Nodal Diameter: This field is active if HI Coupling Method is set to First Extension
of Fundamental Nodal Diameters or All Nodal Diameters. Enter an integer to specify the nodal
diameter range or the maximum number of nodal diameters for which you require an accurate
response. This option is not available if the HI Coupling Method is set to Fundamental Nodal
Diameters.

Note:

Consider the trade-off between accuracy and computational costs when specifying the
nodal diameter range:

– A low number selects a minimal number of harmonic indices, which is compu-

tationally efficient but gives accurate results for a smaller frequency range.

– A high number selects more harmonic indices and provides more accurate results
over a wider frequency range at the price of higher computational costs.

2. Calculate Button: Click Calculate after you have specified all inputs, and the wizard generates two
tables, listing the calculated indices (see step 3) and all analyses that are included in your model
(see step 4).

3. Calculated Indices Table: This table lists the main harmonic indices required for each stage to es-
tablish a baseline of accuracy. These HIs are sent to the analyses selected in steps 4 and 5 for inclusion
in your model.

4. List of Analysis: This table lists all available analyses included in your model. By default, the wizard
sends the calculated HIs to all analyses if you do not select one or more specific analyses from the
list. Alternatively, select checkboxes to send the calculated HIs only to those specified analyses.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 147
Forced Response Add-on

For a list of supported analysis types, see Solving a Multistage Analysis in the Multistage Cyclic
Symmetry Analysis Guide.

5. Send to Analysis: Click this button to send the calculated indices to the respective stages in the
analyses selected in step 4.

Note:

This action resets the solution state of the Stage object to Solve Required, even if
you have previously solved the simulation.

Below are two examples illustrating the application of the wizard using harmonic indices:

Example 3.1: Model with Two Stages (6 and 12 Sectors)

The aim is to find the coupled harmonic indices that match the main harmonic index, HI=1.

Stage Stage
1 2
Sectors 6 12
(N)

Figure 3.4: Nodal Diameter Calculations for Stage 1

Figure 3.5: Nodal Diameter Calculations for Stage 2

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
148 of ANSYS, Inc. and its subsidiaries and affiliates.
 Multistage Harmonic Choice Wizard

Figure 3.6: Harmonic Index Calculations

The first two tables list the nodal diameters for each HI of Stage 1 (Figure 3.4: Nodal Diameter Calculations
for Stage 1 (p. 148)) and Stage 2 (Figure 3.5: Nodal Diameter Calculations for Stage 2 (p. 148)). For Main
Harmonic 1, the coupling nodal diameters are 1 and 5 in Stage 1. In Stage 2, the coupling diameters
(1 and 5) are found to be part of HI 1 and 5.

Table 3 (Figure 3.6: Harmonic Index Calculations (p. 149)) indicates the coupling Fundamental Nodal
Diameters (also referred to as the Main Diagonal) for the Harmonic Indices matrix. The Fundamental
Nodal Diameters are represented by the blue band. The coupling indices are represented in green. The
Fundamental Nodal Diameters represent aliased/main coupling. Since the HI of Stage 2 is an integral
multiple of Stage 1, there are no additional couplings. Therefore, setting HI Coupling Method to First
Extension of Fundamental Nodal Diameters or All Nodal Diameters to request additional indices
does not cause a change in generated Main Harmonic indices.

Example 3.2: Model with Two Stages (6 and 21 Sectors)

The aim is to find the coupled harmonic indices that match the main harmonic index, H=1.

Stage Stage
1 2
Sectors 6 21

Figure 3.7: Nodal Diameter Calculations for Stage 1

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 149
Forced Response Add-on

Figure 3.8: Nodal Diameter Calculations for Stage 2

Figure 3.9: Harmonic Index Calculations

The nodal diameters for each harmonic index of Stage 1 and Stage 2 are listed in Figure 3.7: Nodal
Diameter Calculations for Stage 1 (p. 149) and Figure 3.8: Nodal Diameter Calculations for Stage 2 (p. 150).

If HI Coupling Method is set to Fundamental Nodal Diameters, only the nodal diameters below the
maximum harmonic index of the stage with the highest number of sectors (in this case, 10) are con-
sidered. This corresponds to the nodal diameters in green. This method indicates coupling between
the harmonic index 1 of Stage 1 and harmonic indices 1, 5, and 7 of Stage 2. It is also displayed
graphically in the aliased main diagonal indicated by the blue arrows in Figure 3.9: Harmonic Index
Calculations (p. 150).

If HI Coupling Method is set to First Extension of Fundamental Nodal Diameters, the wizard selects
more harmonics by extending the main diagonal to higher nodal diameters, as illustrated by the orange
arrows in Figure 3.9: Harmonic Index Calculations (p. 150). The process stops at the specified Maximum
Nodal Diameter. For a value of 17 nodal diameters, the extra harmonics 4, 8, and 10 of Stage 2 (in orange)
which also participate in the response are selected. They correspond respectively to the coupling of
the 17th, 13th, and 11th nodal diameters.

If HI Coupling Method is set to All Nodal Diameters, the wizard selects all harmonic indices coupled
below the specified Maximum Nodal Diameter inside and outside of the main diagonal by incrementally
adding HIs starting from the specified Main Harmonic. In that case, the selected harmonic indices are
1 and 2 for Stage 1 and 1, 2, 4, 5, 7, 8, and 10 for Stage 2, as illustrated in Figure 3.10: Harmonic Index

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
150 of ANSYS, Inc. and its subsidiaries and affiliates.
 Multiharmonic Combination

Calculations for All Nodal Diameters (p. 151). Starting from the Fundamental Nodal Diameters (in light
green), it searches for other coupled nodal diameters in those rows and columns below the Maximum
Nodal Diameter (yellow cells) and continues the process to find all couplings by finding the dark green
nodal diameters next. The remaining white cells with a number of nodal diameters under 17 also rep-
resent existing nodal diameter couplings, but with less influence on the input Main Harmonic and are
not output by the wizard.

Figure 3.10: Harmonic Index Calculations for All Nodal Diameters

3.5. Multiharmonic Combination

Multiharmonic combination results expose two objects.
3.5.1. Multiharmonic Plot (DPF)
3.5.2. Multiharmonic Chart

Multiharmonic Plot and Chart provide the composite values of all harmonic responses at different
frequencies in the time domain. The composition of harmonic responses excited at different frequencies
into a time domain signal is done as follows:

To compose such a signal, the fundamental frequency must be established.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 151
Forced Response Add-on

If a solution exists, the solution is periodic and ω0 (the greatest common divisor of all frequencies) is
the fundamental frequency. If a solution does not exist, the signal is not periodic.

The Multiharmonic Plot and Chart objects assume that all loadings are multiples of a greatest common
divisor. Signals are assumed to be periodic, both inputs and outputs of the multiharmonic analysis.

Multiharmonic combination objects are only valid if the solution intervals are equal in all RPMs/Steps.

For derived results like Von Mises stress, the values are first converted to the time domain before
composition.

Explanation of calculations performed

1. Calculation of engine orders

As an example, a multiharmonic analysis can be conducted with the steps defined as shown.

Here,

• Engine Orders = Maximum Frequency value in each step / GCD

• Where GCD is the greatest common divisor of the maximum frequency value in each
step.

In this specific case:

• Engine Orders = [10, 20, 30, 40] / 10

• Engine Order = [1, 2, 3, 4]

2. Calculation of harmonic composite response

DPF operators are used to obtain the result data at each solution interval in each defined step
(RPM value). Another DPF operator fft_multi_harmonic_minmax is used to create a
composite of the harmonic response. For more details on this refer to the fft_multi_har-
monic_minmax operator in the appropriate Data Processing Framework (DPF) manual.

3.5.1. Multiharmonic Plot (DPF)

This is a Python result contour plot of the maximum, minimum or amplitude values of a time domain
signal as a composition of harmonic responses excited at different frequencies. This is only available

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
152 of ANSYS, Inc. and its subsidiaries and affiliates.
 Multiharmonic Combination

as a result under harmonic analysis. For a chosen Set, all harmonic responses are calculated, and total
response is displayed for the chosen result type.

Define By

Allows you to choose between Geometry and Named Selections.

Selection

Allows all FE (Nodes and Elements) and Geometry (Vertex, Edge, and Body) selections.
Results cannot be scoped to mid-side nodes for multiharmonic combination objects.

Set

Drop-down that contains the available sets for evaluation. For example, to evaluate the
composite result of the last frequencies of each harmonic step, select the last set available
in the list.

Time Evaluation

Drop-down that contains Maximum, Minimum and Amplitude.

Result

Drop-down contains Displacement, Stress and Elastic Strain. Elemental results for Elastic
Strain are not supported for this Result object.

Type

This is available when the Result chosen is Stress or Elastic Strain. The available types are
Normal and Shear components for Stress or Elastic Strain.

Orientation

Depending on whether Normal or Shear components are requested, the drop-down offers
different orientation options.

Coordinate System

Drop-down contains Global and Solution Coordinate System.

Integration Point

Drop-down that is available when Result is either Stress or Elastic Strain. Elemental or
Nodal result display options are available.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 153
Forced Response Add-on

3.5.2. Multiharmonic Chart

Inserting this object under the Solution plots a graph containing the synthesized result (the combin-
ation of all harmonics) along with the contribution of each order. This facilitates the identification of
orders and frequencies contributing the most to the overall response.

Scoping Method

Geometry and Named Selections for single nodes and elements. Results cannot be scoped
to mid-side nodes for multiharmonic combination objects.

Domain

Drop-down that contains options to set the plot domain to Frequency and Time.

Result Number of Points

You can choose the number of time domain points used to calculate and display the graph.
Requesting more points leads to a more precise evaluation but at the cost of evaluation time.
By default, an internal algorithm is used.

Number of Cycles Increment

You can choose the number of cycles of the combined signal. The number of cycles is the
number of periods of the fundamental frequency that are shown in the plot. The default
value is 1.

Frequency Set

This option is available only if Chart Type is set to Time Domain. This is used to choose
time domain signal to plot. For example, to evaluate the composite result of the last frequen-
cies of each harmonic step, select the last set available.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
154 of ANSYS, Inc. and its subsidiaries and affiliates.
 Multiharmonic Combination

Time Evaluation

Drop-down that contains options to plot Maximum, Minimum, or Amplitude values.

Results

Expanded results that are available, such as Rotations and Beam Results (DOF results and
Beam SEQV). Refer to the table below to see what is available for each scoping type.

Engine Order Input

Shows a table with detected/calculated orders that you can deactivate by deleting rows.
Refer to Multiharmonic Combination (p. 151) for more information about engine orders.

Calculate Individual Orders

Drop-down that contains the option to select Yes or No. Setting the option to Yes will show
the response of all orders along with the synthesized response. Setting the option to No will
only show the synthesized response.

Y Log Scale

This option is available only if Chart Type is set to Frequency Domain. Sets the scale to
logarithmic if set to True.

X Axis Units

This option is available only if Chart Type is set to Frequency Domain. The drop-down
contains options to set units in RPM, Hz and rad/s.

Limit Search to Range

Allows you to input the minimum and maximum values of each axis manually.

Solver Unit System

This read-only field shows the unit system used to display the object.

After providing the inputs, you can right-click the object and select Generate. This will populate the
chart and tabular columns, showing the synthesized (composite) value of all harmonic responses. If
individual orders are requested, they are plotted as well. The plot contains an option to select and
deselect the orders to display.

A tabular data display also shows the plot values.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 155
Forced Response Add-on

Table 3.1: Allowed results for each selection type

Solid Shell Beams

Node Element Node Element Node
Deformation Normal Stress Deformation Normal Stress Deformati
Velocity Shear Stress Velocity Shear Stress Velocity
Acceleration Acceleration Acceleratio
Rotation Rotation
Angular Velocity Angular Ve
Angular Acceleration Angular A

3.6. Post-processing
Refer to the following sections to refine and view the results of the Forced Response analysis.
3.6.1. Mode Multiplier
3.6.2. Export Results
3.6.3. Fatigue Diagram
3.6.4. Matrices
3.6.5. Optimize Blade Sequences

3.6.1. Mode Multiplier

• Results Part: Amplitude, Real or Imaginary. Amplitude= √(Real2+ Imaginary2)

• Frequency: Drop down of evaluated frequencies

• The values correspond to the plot of the matrix fileaVec.matr.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
156 of ANSYS, Inc. and its subsidiaries and affiliates.
 Post-processing

3.6.2. Export Results

Export tabular results by clicking Export in the result details. The content of the table will be exported
as a csv file in your user file directory. The csv file will then be opened in the default csv editor.

3.6.3. Fatigue Diagram

When the Fatigue Diagram is evaluated or selected in the tree item, it will be displayed as shown
below:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 157
Forced Response Add-on

Here are some key properties in the Details panel of the Fatigue Diagram post-processing object:

• Set Stress Component to either Equivalent (Von-Misses) or Maximum Principal.

• Define the Frequency Range for the alternating stresses. One or several frequencies may be picked
to calculate the alternating stresses.

• Set the Result Part to either Real, Imaginary, Amplitude, Maximum Values Across Phase Angle,
or Phase Angle.

• The static stresses come from the Static Structural analysis. If more than one load step is present
in the Static Structural system, a different load step may be selected.

• The material data strength creates the fatigue line and calculates the life. The available Mean Stress
Theory options and their formulas are:

Goodman:

Soderberg:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
158 of ANSYS, Inc. and its subsidiaries and affiliates.
 Post-processing

Gerber:

ASME Elliptical:

where n is the life, δα is the alternating stress, δm is the steady stress, Se is the endurance strength,
Sy is the yield strength, and Sut is the ultimate strength.

The Mean Stress Theory can be set to Custom. You must define steady vs. alternating stress limit
tabular data.

3.6.4. Matrices

• The Krom and Mrom matrices are displayed.

• Open Matrices opens the Matrices in a csv format in the default editor.

• Copy Matrices copies the matrices in a csv format to the project's user file.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 159
Forced Response Add-on

• For each matrix, the real and imaginary values are displayed or copied. Therefore, 4 matrices
are created by default. (Real Mrom, Real Krom, Imaginary Mrom, and Imaginary Krom)

3.6.5. Optimize Blade Sequences

• The goal is to optimize the order of the mistuning parameter so the maximum amplitude of
the mode multiplier across the frequencies is minimized.

• An initial mistuning must be present.

• The number of random shuffles define the number of times the blade order will be randomly
changed and the result evaluated.

• The best value is then taken as a first point for the iterations. The number of iterations is user
defined.

• While the iteration is running, it is possible to abort. This will save the current best value in
the user directory and close Mechanical.

• Ansys recommendeds using a large number of frequencies. This will not slow down the optim-
ization process while creating better results.

3.7. Troubleshooting
Here is a list of common errors:

• Cannot see the Harmonic indices:

– Restart your computer to reload the libraries.

• All the results in the Harmonic analysis are zeros:

– Make sure the pressures were mapped correctly.

– Ensure that Delete Unneeded Files is set to No in the Analysis settings of the Static, Modal, and
Harmonic systems.

– Ensure that Mistuning and Aerocoupling are defined correctly.

• License error-read only fields:

– Try closing and opening the Mechanical window.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
160 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 4: Explicit Dynamics Add-ons
The following add-ons are available for Explicit Dynamics analyses:
4.1. Drop Test Add-on
4.2.The LS-DYNA Keyword Manager Add-on

4.1. Drop Test Add-on

The Drop Test Add-on comprises a wizard to automate the setup of a drop test analysis within an Explicit
Dynamics or LS-DYNA analysis system from a geometry file of the object to be dropped. Once the Drop
Test Add-on is loaded, you should be able to open the Drop Test Wizard. Activate either an Explicit
Dynamics or LS-DYNA analysis and navigate to the Mechanical Environment Toolbar, then click the
Drop Test Wizard icon to launch the wizard.

Figure 4.1: Drop Test Add-on Showing Loaded Status

For more information about this Add-on, see Using the Drop Test Wizard.

4.2. The LS-DYNA Keyword Manager Add-on

The LS-DYNA Keyword Manager Add-on allows you to enter LS-DYNA keywords as objects in the project
tree when an LS-DYNA system is present. This provides an easy way to insert keywords that cannot be
generated by the Mechanical system into the .k file generated by the system. It is not activated by
default. To load the add-on, simply click the icon in the Add-ons Ribbon.

The Keyword Manager is opened by clicking the Keyword Manager icon in the Mechanical Environment
tab. For more information about this Add-on, see The LS-DYNA Keyword Manager.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 161
 Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
162 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 5: Bolt Tools Add-on
The Bolt Tools Add-on provides helpers and quick actions to automate the standard modeling needs
like creating contacts and preloads. Use the Instance Manager for auto-recognition of geometry and
grouping as well as linking to user-defined modeling routines in Mechanical. User-defined APDL mod-
eling routines are linked to Mechanical coordinate systems.

5.1. Making the Bolt Tools Add-on Available

To make the Bolt Tools capabilities available, click the Bolt Tools Icon in the Add-ons Ribbon. The icon
will be highlighted in blue, indicating that the add-on is loaded.

Figure 5.1: Active Bolt Tools Icon on the Add-ons Ribbon

Once the add-on is loaded, the Bolt Tools Ribbon is visible.

Figure 5.2: Bolt Tools Ribbon

5.2. Bolt Tools Add-on Definitions

Bolt geometry is described in the figures below in terminology typically used in the context of this app.
In general, a simplified representation of a bolt with cylindrical faces for the threaded section is the
only geometry that is supported. Modeling of the full thread is not supported for many of the streamlined
workflows, as this is typically not done for large models with many bolts due to computing resources.
As addressed in other sections, there is a user-configurable framework to help with this type of modeling,
but utilization of this framework will rely on user-defined scripts and inputs.

The head of the bolt can be simplified to a circular representation, or a hex or polygon can be used.

The "Bottom" and "Top" faces are the two faces that are the furthest apart along the bolt axis. The Top
face is the face closer to the centroid of the part, typically where the head would be on a standard
bolt/fastener geometry.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 163
Bolt Tools Add-on

Figure 5.3: Basic Bolt Terms

Below are two other types of modeling that are generally supported and can be auto-recognized. These
involve geometric partitioning of the threaded region. The threads are still cylindrical faces, but they
can be split into a separate section by an edge, or by a step where the radius of the thread section is
different from the radius of the shank section.

Figure 5.4: Bolt Thread Partitioning

5.2.1. Bolt Geometry Auto-Recognition

A feature of the app is auto-recognition of typical bolt geometry features such as the shank, thread,
bottom, top, and head seating faces. These features can be generally recognized in geometries de-
scribed in Bolt Tools Add-on Definitions (p. 163).

For an example of auto recognition see the snippet: Script Snippets/GeometryRecogni-

tion.py

To see details of the geometry recognition routines, see the code module: BoltGeometryRecog-
nition.py

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
164 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Buttons

5.2.2. Object Summary Tables

Object Summary Tables (OST) are available to view a summary of tree objects in tabular form. These
tables can be sorted based on values and present user-defined information. An example of an OST
is given in the app in the directory: <AppInstalldir>\SummaryTables

The example BoltProbes.py is a file that holds code to display Bolt Pretension Probe objects for
the max preload, working load, percent, user-defined allowable, and utilization. Users can add files
to this directory to create customized table data to be pulled into any Mechanical session. To display
a table in Mechanical, select the appropriate file with the specified routines for extracting model
values and performing user-defined evaluations (such as utilizations and factor of safety)

Access to select an OST file for loading into Mechanical is present in multiple menu areas.

5.3. Bolt Tools Modeling Buttons

This section outlines the Selection, Contact, Meshing, Coordinate Systems, Preloads, Beams, Post Pro-
cessing and Tree Helper menu buttons and actions on the Bolt Tools Ribbon. These items can be used
to help streamline the modeling of bolted connections as well as other large assembly models.

Figure 5.5: Bolt Tools Modeling Buttons

5.3.1. Selection
Selection tools are provided to streamline the selection of geometry across a pattern of bodies or
within a body.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 165
Bolt Tools Add-on

Figure 5.6: Bolt Tools Selection Tools

Select Instance Bodies

Selects the bodies in the same Instance Group as the bodies associated with the current selection.

Only the first active entity is used in the selection.

Select Instance Pattern Bodies

Selects the bodies in the same Instance Group as the bodies associated with the current selection,
and attempts to identify separate patterns within the Instance Group.

Only the bodies in the identified pattern are selected.

Only the first active entity is used in the selection.

Select Bodies in Groups Active in Tree

Selects in the graphics all the bodies scoped to any of the active Instance Groups in the tree.

Activate Group from Graphics Selection

Activates the Instance Groups in the tree based on the currently selected geometry.

Select Equal Geom across Instances

Selects the equivalent geometry entities on each body of the Instance Group.

Supports multiple selections.

Select Similar Geom on Body

Attempts to select geometry of the same size and shape within the body associated with the
current selection.

Only the first active entity is used in the selection.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
166 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Buttons

Select Bolt Geometry

Opens a secondary form to select geometry associated with different parts of a bolt.

Go To Selection In Tree

Activates the tree body objects for the current graphical selection.

5.3.2. Contact
Contacts are in integral part of bolted joint modeling and can take a significant amount of time to
setup correctly for large assemblies. Many features and tools are introduced to simplify and streamline
this process. The menu actions are quick and simple, but for more robust actions and creating contacts
refer to Bolt Tools Modeling Wizard (p. 174).

In general, a bolted connection will have two contacts: one for the threaded section and one for the
head of the fastener. The threaded section will commonly have a bonded connection, while the head
will have frictional contact.

Contact via Geometry Selection

Contact scoped with geometrical selections is the most common way to setup contacts. It is a direct
and simply process, but it does have limitations when geometry is not setup in an optimal way.

Using the Mechanical Connection Group object you can use settings for the auto-contact-detection
for cylindrical faces to parse out contacts for thread vs. Head.

Contact via Worksheet-based Named Selection

Named selections based on logical worksheet criteria are powerful objects to allow for maximum
flexibility in the selection process, but this process can be tedious when approached manually. The
Bolt Tools Modeling Wizard provides a set of user inputs to efficiently create contacts via named
selection logic. See Bolt Tools Modeling Wizard (p. 174) for more details.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 167
Bolt Tools Add-on

Figure 5.7: Bolt Tools Contacts Tools

Contact Options and Actions:

Show Bodies In Contact

Shows only the selected bodies and bodies that are associated via a contact pair in the tree.

Activate Contacts from Selection

Activates all contacts in the tree that contain the given graphical selection entities.

This works on any specific entities such as faces, not just the body.

Remove Selection from All Contacts

Removes the graphical selection entities from all contacts in the tree.

Useful for globally cleaning contacts of geometrical entities that should not have contacts,
but perhaps were included in auto contact generation.

Contacts that have all entities removed from a scoping by this action will be deleted.

Remove Selection from Active Contacts

Removes the graphical selection entities from activated contacts in the tree.

Contacts that have all entities removed from a scoping by this action will be deleted.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
168 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Buttons

Keep Contact Faces By Face Type

Removes any faces in the activated contacts that are not the same type as the first selected
face in the graphics.

Example:

• Select a planar face in the graphics

• Activate any contacts for clean up

• Run the code to remove any non-planar faces from the activated contacts

Contacts that have all entities removed from a scoping by this action will be deleted.

Activate Named Selection for Contacts

For contacts scoped to Named Selections this will activate the named selections in the tree
for quick reference.

Contact Results Wizard

This wizard creates post processing objects related to contacts, and exports multiple images
to files as well as Microsoft PowerPoint presentations.

Contact Status Export Wizard

This wizard exports the contact status summary for selected contact objects from the Outline
tree.

5.3.3. Meshing
Under Mesh options you can use the Add Mesh Copy capability.

Add Mesh Copy

Add a Mesh Copy control. This is useful to copy a mesh from one bolt to others in the pattern.
Select equal faces of all bolt instances and the mesh copy scoping will be completed on that
selection.

5.3.4. Coordinate Systems

Coordinate systems (CS) are important objects that are often used by other objects for definition.
Creation and manipulation of multiple CS along a pattern can be done via these menu commands.

Bolts Body Coordinate Systems Conventions

For a bolt body a convenient coordinate system for later use in named selections is a cylindrical CS
on the bottom face of the bolt. The convention is to point the Z axis towards the head of the bolt.
This convention is used in the creation of bolt contacts.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 169
Bolt Tools Add-on

Figure 5.8: Bolts Body Coordinate Systems Conventions

Figure 5.9: Coordinate Systems Options and Actions

The following methods are used for CS creation and easy manipulation:

Add CS for Selection

Adds a coordinate system for each geometrical entity selected.

Each entity will get its own cartesian coordinate system located at its centroid.

Z axis will be set to be primary and aligned with the associated geometrical entity.

Flip Z Axis

Add a CS transformation to each activated CS to flip the Z axis.

The following methods work specifically with the convention of a bolt CS being cylindrical and attached
to the bottom face of a bolt.

Add Bolt CS

Adds a CS based on entity selection in the graphics window. Any entity types (Faces, edges, etc..)
can be selected, but the routine will work with the associated bodies.

CS will be in the standard convention for a bolt:

• Cylindrical

• Attached to the bottom face

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
170 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Buttons

• The routine will attempt to determine the bolt axis, then find the furthest faces from the
centroid along that axis (top and bottom faces)

• The face that is furthest from the centroid will be designated the bottom face, and will be
the origin of the CS

CS created will be grouped into a folder in the tree.

Get Bolt CS

Activate CS for a body that fit the standard convention for a bolt CS.

5.3.5. Preloads
Bolt preloads are an integral part of the bolted joint analysis and simulate the tensioning assembly
of the bolt, typically, prior to other loads being applied. The bolt body is cut into two sections and a
pilot node is used to apply this modeling practice. Application of a preload can either be to a cylindrical
face, or to a body. When scoped to a body, a coordinate system must be identified in order to establish
the location of the cut section along the bolt axis.

Consideration must be taken that the split in the body is located outside of a bonded contact section,
which is typical of a bolt thread. In order to do this, often it is important to control the split of the
body based on a coordinate system.

In addition to the split, the preload values can be implemented by step. Functionality to import/export
the preload table values is exposed in this menu.

Assign Preload Cs

Attempt to associate the selected preloads with the closest CS to the body centroid.

Move Preload Cs

Shows small window for user input to move the coordinate system of all activated preloads in
the Z direction.

Useful for modifying the location of the cut section in the bolt to avoid any bonded contact in
the threaded section.

Get Preload From Cs

Select any corresponding preloads from the currently active coordinate systems.

Get Cs From Preload

Select any corresponding coordinate systems from the currently active preloads.

Get Preloads From Selection

Select any corresponding preloads from the graphics window selection.

Set Selection From Preloads

Select in the graphics all the scoped entities for the active preload objects in the tree.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 171
Bolt Tools Add-on

Get Preloads From Probes

Activate preload objects under an analysis based on the active preload probes under the solution.

Rename Preloads Based On Def

Auto-rename all selected preloads.

Export Preload Values

Export the tabular data load values to an external file (.csv) .

Import Preload Values

Import tabular data values from an external file to activated preloads.

5.3.6. Beams
Supports modeling and evaluation of bolts as 1D beam elements.

Figure 5.10: Beams Options and Actions

Show Summary Table

Opens a dialog to select an Object Summary Table (p. 165) for display.

Create Beams from Solids

Creates beam objects with linked remote points, named selections and coordinate systems, for
current graphical selection.

5.3.7. Post Processing

Supports modeling and evaluation of bolts as 1D beam elements.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
172 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Buttons

Figure 5.11: Post Processing Options and Actions

Show Summary Table

Opens a dialog to select an Object Summary Table (p. 165) for display.

Reaction Probes Wizard

This wizard creates post processing reaction probes for forces and moments at various locations
and time points. These are then exported easily to a summary file in .csv format.

Connections Post Wizard

Opens a post processing wizard for viewing time history results for multiple beam, joint, or user-
element data.

Use in cases where you have exported tabular data from an APDL snippet and want to reference
the data back to Mechanical via the APDL element number.

5.3.8. Tree Helper

Contains useful tools for navigating large tree structures and cross referencing of objects.

Figure 5.12: Tree Helper Options and Actions

Object Connections Tree

Opens a secondary object tree with referenced objects underneath it for quick cross referencing.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 173
Bolt Tools Add-on

Show Tree Helper

Opens secondary window of quick key options for filtering the model tree or setting visibility.

Tree Group Helper

Opens a pane for selecting objects based on group or folder in the tree.

Useful for selecting grouped objects and modifying properties in the details window in mass up-
dates.

Provides for user-filtering tools to get the objects desired quickly.

Object External Data Viewer

Opens the wizard interface to display external .csv files and cross reference rows to objects in the
tree (see External File Data Viewer (p. 175)). You can specify columns for the object IDs for cross
referencing.

Object Selector

Opens the wizard interface to help select objects in the tree based on user criteria (see Select
Objects (p. 175)).

5.4. Bolt Tools Modeling Wizard

The Bolt Modeling Wizard is a streamlined interface for model setup of typical fastener assemblies.
Similar to the main menu items, it is organized into tabs for each category of object, such as: coordinate
systems, contacts, meshing, etc. The wizard is created to allow for more complex user inputs to designate
how a workflow should perform, as compared to a single button with pre-programmed assumptions.

The controls in the wizard have contextual help tool tips that appear when the mouse is over them.
Refer to the Wizard controls and local help for case-specific help. Access for opening the panel and
getting started is directly from the app ribbon menu as shown below.

Figure 5.13: Bolt Tools Wizards Button

5.4.1. Common and Reused Wizard Tabs

Each wizard tab contains multiple controls with which you can interact. Most controls have tool tips
that appear when the mouse is over them, providing contextual help for each type of control. Many
tabs also contain sub-tabs including a Help tab that provides a short summary of the usage and tips
for the given context.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
174 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Wizard

Functions are also available based on the current tree selection, such as export of a summary report,
and the tab controls streamline the selection process when the tree contains many objects.

These are tabs that are reused across multiple wizards:

Select Objects
The purpose of this tab is to facilitate the selection of multiple objects in the tree structure. A parent
tree node can be selected, and children can be filtered by type and various other properties. There
are many workflows that utilize the current tree selection, and this tab helps to streamline that selection
process for generic downstream actions.

External File Data Viewer

The purpose of this tab is to view and cross-reference data from an external file to Mechanical objects.
For example, when a file contains fatigue values for multiple beam objects/elements in the model
and you want to identify quickly all the objects that are above a certain value.

This tab has multiple sub-tabs:

Data File Format

This tab identifies the format, including the row at which the data starts and the column
used as an identifier for the Mechanical objects.

Data Table

This tab displays the external file data and is interactive with the Mechanical interface.

Reaction Probes
This tab is used to create post-processing reaction probes for forces and moments at various locations
and time points. These can then be exported easily to a summary file in .csv format.

This tab has multiple sub-tabs:

Create

The purpose of this tab is to create multiple Reaction Probes to identify forces and moments at
multiple selections. The selections can be geometry entities, contact objects or construction surfaces
that are dynamically created by the wizard. In addition to multiple locations in the model, you
can select multiple time points for reaction probe creation.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 175
Bolt Tools Add-on

Figure 5.14: Reaction Probes Create Tab

Figure 5.15: Contacts under Reaction Probes Create Tab

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
176 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Wizard

Reporting

The purpose of this tab is to export data from multiple Reaction Probes into a single file for
further viewing or manipulation using external tools. Basic data such as the location, time point
and associated values will be included in this report.

Figure 5.16: Reaction Probes Reporting Tab

5.4.2. Wizard Interfaces

There are multiple wizards that are used to streamline the user interface for adding and modifying
objects in the model. These wizards provide several different workflows and have different scopes.
Most of the wizards are used to create objects in the model tree and keep them organized, grouped,
and named easily while using bolt geometry recognition to streamline complex setups.

Many wizards use multiple, nested tabs for different inputs and some tabs are reused across multiple
wizards.

The following wizards are available:

5.4.2.1. Setup Wizard
5.4.2.2. Surface Body Hole Detection Wizard
5.4.2.3. Cone of Compression Imprint Wizard
5.4.2.4. Reactions Probe Wizard
5.4.2.5. Connections Post Wizard
5.4.2.6. Contact Results Wizard

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 177
Bolt Tools Add-on

Figure 5.17: Bolt Tools Wizards Menu

5.4.2.1. Setup Wizard

This wizard is primarily focused on the setup steps and includes the following tabs:

Coordinate Systems
The purpose of this tab is to create multiple coordinate systems.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
178 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Wizard

Figure 5.18: Coordinate Systems Tab

Mesh
The purpose of this tab is to create mesh controls that are typically used for meshing of bolt
hardware, including:

Mesh Copy

Copy a mesh from one body to multiple other bodies.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 179
Bolt Tools Add-on

Axisymmetric Sweep

Create an organized mesh for components that can be swept around an axis.

Mesh Sizing

Sizing of different user or auto-identified regions of a bolt. There are options available to include
sizing for shank, thread, and seat faces of the bolt body. If the shank, thread, and seat faces are
not selected explicitly, these are automatically identified for bolts selected in the geometry tab.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
180 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Wizard

Figure 5.19: Mesh Tab

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 181
Bolt Tools Add-on

Named Selections
The purpose of this tab is to create Named Selections of multiple items. Named selections of each
individual entity in the selection can be created easily.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
182 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Wizard

Figure 5.20: Named Selections Tab

Pretension
The purpose of this tab is to create bolt Pretension objects and associated results probes. Bolt
pretension can be created for 3D geometry or beams, and the location of the pretension split can
be directly input or inferred from geometry recognition with keyword inputs. The supported ana-
lysis types include Static, Transient, and LS-DYNA.

It is mandatory to select at least one analysis object in the Pretension wizard. Multiple analysis objects
can be selected. Depending on the type of selected analysis (i.e. Static, Transient, or LS-DYNA),
different load definition tabs are added to the panel.

Note:

Click Get Load Definition Options every time the analysis objects are altered. For LS-
DYNA analyses, the load definition options are updated, hence supporting the geometry
and beam connection scoping.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 183
Bolt Tools Add-on

Figure 5.21: Pretension Tab

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
184 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Wizard

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 185
Bolt Tools Add-on

Contacts
The purpose of this tab is to create bolt contact regions. This includes separate contacts for the
Head and Thread regions. There are many dimensional inputs for you to manually input or auto-
detect. These inputs are then used in Named Selection worksheet logic to identify the correct re-
gions in the model for the contacts.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
186 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Wizard

Figure 5.22: Contacts Tab

5.4.2.2. Surface Body Hole Detection Wizard

This wizard is used to detect mating holes in surface body assemblies. Once identified, objects such
as Mesh (p. 179) controls, and connections such as Beams can be created to model fasteners.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 187
Bolt Tools Add-on

Figure 5.23: Hole Detection Tab

This wizard features the following tabs:

Create

The purpose of this tab is to detect and create connections between holes. Beams and
Contacts can be created to make connections. Details as to how the model should be
connected are defined in the sub-tabs.

Results

The purpose of this tab is to display the created objects from the workflow.

5.4.2.3. Cone of Compression Imprint Wizard

This wizard creates imprints on the geometry which is in contact with bolts. The imprint face sizes
are generated automatically, respecting the conical assumption of the clamp zone. In the Bolt
Geometry section, bolt bodies are selected and used as imprint guides.

Note:

The Bolt geometry must be a single body part.

You can select the geometry where the imprint is required. If the Imprint Geometry option is left
blank, all active bodies are taken into account. All the geometric bodies that must be ignored during
the imprinting process must be selected using the Ignore Geometry option.

There are further options:

• Auto Remove Bolt Hardware: This automatically detects washers and nuts, and removes
them from imprinting. Where there is no washer, the body in contact with the bolt head is
removed from imprinting (even if it is explicitly selected in the Imprint Geometry section).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
188 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Wizard

• Open SpaceClaim: This opens SpaceClaim to update the geometry.

• Save Backup of Current Geometry: This is a backup of the current geometry, which is saved
in the working directory. This geometry can be retrieved using the Revert Geometry option
under Imprint.

Note:

This option will not save the history of all the changes made to the geometry.
For example, if the imprint operation is carried out in multiple steps, it will
not automatically save the initial geometry (the first geometry on which the
imprint operation was performed).

• Refresh Geometry: With this option, the geometry is updated and imported in Mechanical.
This will not allow the option to explicitly open SpaceClaim.

In the Detection section, a Compression Cones preview can be visualized and imprint faces can
be activated. The Imprint Geom Now option starts the geometry modification process in SpaceClaim.
Depending on the selected option, the modified geometry can be refreshed automatically in
Mechanical (without opening SpaceClaim) or the geometry can be imported manually in Mechan-
ical.

Figure 5.24: Cone of Compression Imprint Wizard

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 189
Bolt Tools Add-on

5.4.2.4. Reactions Probe Wizard

This wizard utilizes the Reaction Probes (p. 175) tab.

5.4.2.5. Connections Post Wizard

This wizard is used to display and export data on connection objects. Beams and Joints are currently
supported. This wizard does not create post objects in the Mechanical tree, but directly accesses
the analysis results file and extracts data that is displayed in the interface or exported to a file.

This wizard has a Connection Objects tab, which contains multiple sub-tabs:

APDL Info

This tab is used to identify and/or export the APDL element and Node IDs for the Mechanical
objects.

Figure 5.25: APDL Info Tab

Beams

This tab is used to review data for Beam objects.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
190 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Modeling Wizard

Figure 5.26: Beams Tab

Joints

This tab is used to review data for Joint objects.

Figure 5.27: Joints Tab

Results Table

This tab is used to display the results. There are three definitions for a given result value: the
Result Type, Location or Element, and Time. For example, Axial Stress at Element 124 at
Time equals 3.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 191
Bolt Tools Add-on

5.4.2.6. Contact Results Wizard

The purpose of this wizard is to create post-processing objects related to contacts, and to export
multiple images to files as well as Microsoft PowerPoint presentations.

This wizard has a Contact Tool Results tab, which allows you to create post-processing objects
related to contacts, and to export multiple images to files as well as Microsoft PowerPoint
presentations.

This tab contains multiple sub-tabs:

Create Contact Results

This tab is used to create contact results such as Pressure and Status contours. These can be
created for multiple locations and time points.

Figure 5.28: Create Contact Results Tab

Image Export Options

This tab is used to create images of the Contact Result contours and save them to a file.

Figure 5.29: Image Export Options Tab

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
192 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Instance Manager

Report Generation

This tab is used to export created images to a Microsoft PowerPoint presentation in a grid
format.

Figure 5.30: Report Generation Tab

5.5. Bolt Tools Instance Manager

The Instance Manager is a custom object that can be inserted into the Mechanical tree. Only one object
of this type is allowed, as this applies to the current model geometry. Users can insert Instance Groups
under the Instance Manager to designate geometry into groupings and associate it with standard parts
from the Part Library (p. 197).

The Instance Manager can auto-create Instance groups for the entire model. This consists of identifying
bodies with the same volume and material and putting them into a group together.

Figure 5.31: Bolt Tools Instances Button

5.5.1. Instance Manager Properties

On Selection

Determines the behavior when selecting an Instance Group (p. 194).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 193
Bolt Tools Add-on

Auto Creation/Tolerance

Tolerance used to compare volumes of parts.

Example: 0.001 = 99.9%-100.1% is acceptable.

Auto Creation/Min. Number

Only Instance Groups with more bodies than the Min. Number will be created.

This avoids creating Instance Groups for all bodies in the model and only focusing on bodies in
patterns of a certain size.

5.5.2. Instance Manager Geometry Selection

Often with repetitive geometry it is efficient to select all the same entities of each individual body in
the group. When using the Instance Manager selection of geometry across the pattern is done based
on the local index of the entity. For example, if you select a face on a body, the Instance manager
can be used to extract the face index local to that body, and then select the same face on each body
in the pattern.

5.5.3. Instance Groups

Instance Groups are created under the Instance Manager. They are associated with user-specified
bodies in the model and can be linked to standard parts.

Some key aspects of Instance Groups and how they are different from a Named Selection are:

1. Although you can specify any body in the model to be in an arbitrary group, typically Instance
Groups are used to identify the same body that repeats in the model, like a bolt.

2. Scoping of a body from one group automatically removes it from another. Bodies cannot
belong to more than one group.

3. Instance Groups can be linked to a standard part, and therefore to a standard routine for
model setup to streamline the workflow.

4. Instance Groups can be auto-generated for the entire model to avoid user time to set up
manually.

Users can edit groups after auto-creation.

5. Instance Groups can be used to select the same geometry across the bodies in the group.

For example, a bolt head contact face can be selected in the graphics on one bolt and then
easily extended to the same face on all other bodies in the group.

Running a Standard Script from Instance Group

One of the key features of Instance Groups is the ability to trigger user-defined scripts to fully automate
the modeling of these parts.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
194 of ANSYS, Inc. and its subsidiaries and affiliates.
 Bolt Tools Instance Manager

Once you set Is Standard Part to Yes, options will appear to select a part from the app library. Once
the part is selected, you can select a Py File to run for this group. The user also has the ability to
send user arguments to the python routine via "User Arg<x>" properties.

After selecting the proper part and routine, to trigger the actions use the menu button under In-
stancesRun Standard Part Scripts From Selected. The appropriate modules will be imported and
the method "Run", which is a required method definition in the module, will be run. The app will also
send global variables that can be used which are described in Standard Variables and Header

5.5.4. Instance Group Properties

Scoping

Determines the behavior when selecting an Instance Group

Definition/On Selection

Determines the behavior when selecting an Instance Group

Definition/Is Standard Part

Toggle to determine if the Instance Group is linked to a standard part from the Part Library

If Yes, the Standard Part Data property section will be visible.

Linking a standard part to the Instance Group can be done manually (drop-down) or automatically
via the Part Library (p. 197) window interface.

Standard Part Data/Name

Name of the standard part from the Part Library

Standard Part Data/Description (Read Only)

Description for the standard part from the Part Library

Py File

Name of the Python file you want to run

This is based on the context of the model and what modeling approach you want for this part
in context.

User Arg 1, User Arg 2, and User Arg 3)

These are text-based arguments that are given to the global scope of the part script module to
allow users context-based options at runtime. These will be given as global variables "UserArg<x>"
where x = 1, 2, or 3 based on the user argument used.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 195
Bolt Tools Add-on

5.5.5. Geometry Selection

Selection of geometry is a basic aspect of modeling that must be efficient. Patterned geometry that
includes multiple equal instances lends itself well to methods that identify the same geometry across
the pattern.

Figure 5.32: Instances Options and Actions

Select Instance Bodies

All bodies that are determined to be the equal will be selected.

Select Instance Pattern Bodies

All bodies that are determined to be equal same and in the same pattern will be selected.

A pattern is determined based on the proximity of bodies to each other.

Select Equal Geom Across Instances

Selects the same face, edge, etc. on each body that is determined to be equal.

Example: The 2nd edge of the 3rd face of each equal body

Select Similar Geom on Body

Based on context, try to select the same geometry

Based on same length, surface area, etc.

Use this to select similar geometry on the same body. Use other methods to select geometry
across multiple bodies.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
196 of ANSYS, Inc. and its subsidiaries and affiliates.
 Instances - Part Library

5.6. Instances - Part Library

Figure 5.33: Accessing the Parts Library

A part library is utilized to automate the modeling of standard parts represented as bodies in the
model. With a predefined file that contains part information like material, volume and name, you can
uniquely define criteria to identify a specific part. Once identified, this part can be mapped to standard
scripts which will control the setup. This can include meshing, loads, material selection, contacts, post
objects, or any other modeling setup. More than one script file can be used to account for different
modeling approaches taken on the same part based on the analysis context. For example, sometimes
you may want to represent a bolt with full solid elements, while other times a beam-representation
may be appropriate.

The Part Library concept works in conjunction with Instance Groups (see Instance Groups (p. 194)) objects
in the model tree. Instance Groups can be inserted under the Instance Manager to link the standard
part information to specific bodies in the model.

5.6.1. Part Library Interface

To open the Part Library use the main Bolt Tools ribbon under Instance ManagerPart Library. This
will open a new window to work with parts.

The list on the left contains all the parts in the library, and the list on the right will be all the identified
Instance Groups (see Instance Groups (p. 194)) in the current model.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 197
Bolt Tools Add-on

Figure 5.34: Part Library Window

5.6.2. Adding a Part to the Library

There are three main ways to add a part to the library.

Adding a Part: Manual File Creation

To add a part to the library you can directly create new files in the proper directory with the proper
format. This is described in Part File Structure and Format (p. 199). Add and modify files directly as
you would any file on your system. Since the files are simply text files, any common text editor can
be used to modify these files.

Adding a Part: Import from .csv format

In the Part Library interface, you can use Library ActionsImport Parts from .csv to import multiple
parts and create multiple files in a single operation. Note that existing files with the same names will
be overwritten in this action, and this cannot be undone.

See the example file for format: AppInstallDir\PartLibraryData\Example csv im-

port.csv

Adding a Part: Add from Selection

Use the option Library ActionsAdd Selection as Part to have the current selections from the current
model list (on right) be added as a part file in the library. These files will contain the basic data that
can be extracted like material, volume, etc. Users will still need to open these files and modify them
to the correct methods and matching criteria, which cannot be set automatically from model context.

A part will be created for each selection in the list. If no selection is active, a part will not be created.

5.6.3. Referencing and Using a Part from the library

To reference a part from the library, open the Part Library window from Mechanical. You can use
ActionsMatch Parts to match parts from the library to your current model. Parts will be identified
according to the designated matching criteria (see Part Auto-Recognition and Matching Criteria (p. 200))
in the part definition file. Prior to matching, or if a match is not found, the Part column will list "None".

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
198 of ANSYS, Inc. and its subsidiaries and affiliates.
 Instances - Part Library

Figure 5.35: Referencing and Using a Part from the Library

5.6.4. Part File Structure and Format

The Part Library consists of Parts that are defined via a simple text file with standard format. Part files
should be placed in this directory: AppInstallDir\PartLibraryData

You can also use folders within this directory to organize files. The library will load any .txt files in
the main library directory recursively. An example file with format is located in this directory for ref-
erence as well.

Property Description Example

Description User-description of part Bolt Example for app
Material Name Material Name Structural Steel
Number of Number of Bodies in group. 1 is only supported 1
Bodies value at this time
Number of Total number of faces on the bodies 13
Faces
Volume Total volume of all bodies 8.49471222694e-07
Script File Name Name of python script file(s) to run for standard ValveBoltsSolid,ValveBoltsBeams
part. Use "," to separate multiple file options.
User Defined Use this as any user defined data
Data
User Defined Use this as any user defined data
Data
User Defined Use this as any user defined data
Data
Matching Script Name of python script file to use for matching this Standard
part to the model bodies

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 199
Bolt Tools Add-on

5.6.5. Part Auto-Recognition and Matching Criteria

Users can define a custom python-based routine for recognizing parts. This can be done by introducing
a new module in the path: AppInstallDir\PartLibraryData\MatchingCriteria

This is not required as a module is included in the basic installation called Standard.py. This
module can be used as an example of how users can create additional similar modules with custom
functions for part recognition. Standard Parts without a matching script defined will use the default
Standard.py module criteria.

In this path a new module can be created with a function defined with the name: "IsBodyGroupThis-
Part". This function will take the arguments from the table below, and should return a boolean
True/False to determine if there is a match for the BodyGroup to the Standard Part.

Property Description
ExtAPI Extension API Global
Quantity Ansys.Core.Units.Quantity type
Part Standard Part Class Object
BodyGroup InstanceManager BodyGroup Class Object that is being evaluated.

5.6.6. Part Script Files

Parts in the library can be mapped to one or multiple python script files, which can be run in a batch
mode by the app. The files are located in: AppDirectory\PartLibraryData\PartScripts

Standard Variables and Header

When running the script files, some basic information and variables will be defined globally in the
module scope. See below for an example of the header variables that should be in the global scope
of any standard part file module. The values are provided by the app internally, and should generally
be set to "None" to initialize them in the module. These are then usable in the main routine of the
module.
ExtAPI = None #Ansys application extension objects
Ansys = None #Ansys Namespace
Enums = None #Ansys.Mechanical.DataModel.Enums
Quantity=None #Ansys.Core.Units.Quantity
Model = None #ExtAPI.DataModel.Project.Model

InstanceGroup = None #InstanceFinder.InstanceGroup class object

Part = None #PartLibrary.Part class object
#Text values given by user at run time via InstanceGroup Obj props.
UserArg1 = None; UserArg2 = None; UserArg3 = None

Standard Routine Name

The application will automatically trigger the function in the module named "Run" which is a method
that takes no arguments ("def Run():"). There can be other methods contained in the module, but the
method that will be run automatically by the app will only be this "Run" method. Triggering the
method via the app GUI is described in Running a Standard Script from Instance Group (p. 194)

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
200 of ANSYS, Inc. and its subsidiaries and affiliates.
 APDL Bolt Modeling

5.7. APDL Bolt Modeling

APDL is a language/solver used by Mechanical and for parts that have a standardized method for
modeling, an APDL-based setup can greatly reduce the amount of work required in Mechanical. To ac-
commodate this and integrate in Mechanical, a custom object has been created to allow for users to
direct user-defined APDL input based on selected coordinate systems in Mechanical and a list of user-
defined standard parts.

The use of APDL-based modeling has the advantage of simplifying the Mechanical model, but it demands
that you understand how to integrate APDL commands into the main APDL input being generated by
the Mechanical model. You will have three distinct sections for which commands can be applied:

Pre

Commands are created prior to load creation, but after geometry, contacts and other model aspects
are generated.

Solve

Commands are created at the end of load input, but before SOLVE command

Post

Commands are input just after the SOLVE command

5.7.1. APDL Bolt Mechanical Tree Object

The way to utilize this functionality is to introduce an APDL Bolt object in the Mechanical tree. This
object will allow you to select parts from a user-created library. There are four parts that can be in-
cluded in an APDL Bolt object: bolt, bolt washer, nut, nut washer.

Once the parts are selected, you can specify an offset for the nut/nut washer section, as this will be
case-specific to the model. To introduce multiple instances of this assembly to the model, you can
select coordinate systems. These will be used to define where in the model to show the graphical
representations, and the coordinate system information will be passed to the APDL input file such
that they can be used to create the FE entities required at the user-specified locations.

Convention: It is assumed the coordinate system is located along the bolt axis at the head of
the bolt with Z axis pointing towards the threads.

5.7.2. APDL Bolt Part Files

An APDL Bolt part file is used to specify the APDL inputs, graphical representation in Mechanical, and
the APDL commands sent to the solver input file at solve time. The format is an XML file with sections
associated for each of these tasks.

Tag Options Value Notes

Type
Input Send a value to the APDL input file to be used in
the standard routines to follow.
ApdlName Text Name of the APDL variable that will be assigned.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 201
Bolt Tools Add-on

Description Boolean User given description of the input. Does not

effect the code or APDL, only for user notes
Type Text Flag to denote what type of input it is. For a
Quantity Accepted values are: Text, Quantity, Float
QuantityName Text Name of the Quantity like "Force", "Length" etc...
Head Radius, Height, Text Reference to the APDL Input that drives this
HeadType graphical dimension/option. HeadType = 'Hex' will
denote Hex-head display.
Shank Radius, Height Text Shank section of a bolt
Thread Radius, Height Text Thread section of a bolt
HeadFlange Radius, Height Text Optional for a bolt. Head part that is a flange.
Height is NOT additive to the <Head> height.
Preload Radius, ZLoc Text Preload will show as a circular ring at given radius
and axial (Z) location.
Nut Radius, Height, Text Nut is only a single section. Note, that an inner
HeadType diameter is not used in the graphics.
Washer Radius, Height Washer is only a single section.Note, that an inner
diameter is not used in the graphics
File Sends the text of the file to the input stream.
CopyAs Text Will use APDL commands to copy the file to the
working directory at run time instead of inserting
the text of the file into the main input file. Use
this when you want to copy a macro file and not
put directly into the input stream.
SendOnceOnly Boolean Send the text of the file only once to the input
file stream. Use this when you need the
commands for the part, but only once in the entire
file. Example: creating a material that is common
to many parts.
IterateBlockIds Boolean If you are using pre-meshed data in the EBLOCK
and NBLOCK form, you will need to iterate the IDs
in the part files (that likely start at 1) to the current
next-available ID from Mechanical.
UpdateMechRefIds
AttributeName Text Name for an attribute to attach to the Mechanical
object sending the information. This attribute can
be used to identify the in-creation node, element,
or type ID for a given part in the assembly.
IterateMechRefIds Iterate the IDs of Mechanical by the given
amounts in order to avoid any clash with
Mechanical as it continues to create the input file.
Node integer Update the counter for given object
Element Integer Update the counter for given object
Type* Integer Update the counter for given object

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
202 of ANSYS, Inc. and its subsidiaries and affiliates.
 APDL Bolt Modeling

PerCoordinateSystem Boolean Option to multiply the iteration by the number

of Coord. Sys.

5.7.3. APDL Bolt Properties

The APDL Bolt object has the following properties:

Parts

Bolt

Bolt Washer

Nut Location (User-specified based on modeling context)

Nut

Nut Washer

Coordinate System Selections

Defines the coordinate systems for the APDL input.

The coordinate system Ids are sent to the APDL input file prior to the user-defined commands.

Coordinate System APDL array can be referenced to create and orient fastener nodes/elements
in the main model

Display

Visible (Option for if graphics are visible even when object is not selected.)

Depth Test (Option for graphics to be "on top" of other graphics.)

Transparency

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 203
 Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
204 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 6: optiSLang 3D Postprocessing Add-on
The optiSLang 3D Postprocessing Add-on helps Ansys Mechanical to interact with optiSLang 3D Post-
processing. It enables the use of empirical and free-form random field models to generate random
geometric imperfections and apply displacements to the nodes on a part of the model's boundary. It
also allows export of results to optiSLang 3D Postprocessing for statistical analysis and Field-MOP creation.
For more information about this add-on, see Getting Started with oSP3D.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 205
 Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
206 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 7: Restart Analysis Add-on
The Restart Analysis Add-on makes Static-Static or Transient-Transient Structural restart capabilities
available within the Mechanical environment.

Loading the Restart Analysis Add-on

To make the Restart Analysis Add-on capabilities available, click the Restart Analysis icon in the Add-
ons Ribbon. The icon will be highlighted in blue, indicating that the Add-on is loaded.

Once the Add-on is loaded, the Restart Analysis toolbar is visible.

To unload the Add-on, simply click the Restart Analysis icon in the Add-ons Ribbon again.

Creating a Restart Analysis

Creating a Restart Analysis produces a new analysis system in Mechanical, which can be restarted from
a selected Base Analysis system by following these steps:

1. Select any Static or Transient Structural analysis system in the tree view in Mechanical.

2. Click Create Restart Analysis in the Restart Analysis toolbar. If all criteria are satisfied (i.e., Restart
Files must be retained, etc.), a new analysis system is created with a Restart Setup object
already added to it. Otherwise, set the options in the Base Analysis. The new analysis system
is created with all the appropriate settings. For more information, see Restart Analysis System
Criteria (p. 211).

3. Add your loads and boundary conditions. For more information on acceptable loads and
boundary conditions, see Limitations for Loads and Boundary Conditions (p. 212).

4. Configure the settings in the Details panel of the Restart Setup object.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 207
Restart Analysis Add-on

Restart Setup Object

This object is used for an existing analysis system that you want to use as the Restart system.

Restart the setup by following these steps:

1. Select your chosen analysis system.

2. Click Restart Setup Object in the Restart Analysis toolbar to insert this object under the selected
analysis and proceed with restarting the analysis.

These properties are available for the Restart Setup object:

Restart from System

Choose any valid analysis system from the drop-down menu in this property. The analysis list is
filtered based on the Restart Analysis type. If the Restart Analysis system is Static Structural, only
the remaining Static Structural systems will appear in the list.

To perform a Static-Transient or Transient-Static restart, use Transient Structural systems for both
the Base and Restart Analyses and set Time Integration to either On or Off as appropriate.

Select Restart Loadstep

This property has two options:

• Last Load Step (Default): This is the default option. It uses the last load step of the selected Base
Analysis to restart the analysis.

• Manual: If there are restart points available at multiple load steps in the Base Analysis, use this
option to manually specify a load step number to restart from.

Force Base Analysis Solve

No is the default option for this property. When solving the Restart Analysis, selecting Yes forces
the Base Analysis to solve before starting the Restart Analysis solution. This option is recommended
only for batch analyses such as a Design Point study.

Store Results For

This property has two options:

• Only Restarted Steps (Default): When this option is selected, only the results for the restarted
steps are saved and available for post-processing.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
208 of ANSYS, Inc. and its subsidiaries and affiliates.
 • Base + Restarted Steps (Full Time History): When this option is selected, all the load step
results are saved, that is, both the Base Analysis steps and restart load steps. This increases
the size of the results file for the Restart Analysis.

Load Applied by Surface Effect (Restart)

Adding loads that create new elements is not permitted when using the Restart Analysis Add-on. An
example is loads such as Pressure or Force when Applied By is set to Surface Effect instead of Direct.

If the Base Analysis has loads (Pressure or Force) applied by the Surface Effect option, these loads can
be further modified in the Restart Analysis by following these steps:

1. Select the analysis system where the restart is being performed.

2. Click Load Applied by Surface Effect (Restart) in the Restart Analysis toolbar, or right-click the
analysis system and select Insert > Load Applied by Surface Effect (Restart).

3. Configure the settings in the Details panel:

Each property is described below:

Load Object

This contains a drop-down menu of all the Pressure and Force loads present in the selected Base
Analysis (the analysis selected in the Restart From System property in the Restart Setup object).
Only Pressure and Force loads with the Applied By property set to Surface Effect and Magnitude
defined as Constant or Tabular are supported.

Data Format

It has two options:

• Constant: This is the default option. It applies a constant load ramped over the Restart load
step.

• Tabular: This option defines the Time vs Load data.

Magnitude or Component X,Y, and Z

Depending on whether the Define By property in the Details panel of the load (Pressure or Force)
is set to Components, Vector, or Normal To, this property can be set to Magnitude (for Define
By set to Vector or Normal To) or X Component, Y Component, and Z Component (for Define
By set to Components).

Note:

The following aspects are not supported in the Base Analysis:

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 209
Restart Analysis Add-on

• Surface Effect-based Force loads in the Base Analysis with Independent Variable set
as Step: To remediate, set Independent Variable to Time.

• Force loads scoped to Nodes/Vertices in the Base Analysis with Independent Variable
set as Time: To remediate, set Independent Variable to Step.

• Force loads that are scoped to Nodes/Vertices, if Base Analysis is a Transient Structural
analysis: To remediate, use Nodal Forces instead in the Base Analysis.

The following aspect is not supported in the Restart Analysis:

• Pressure/Force loads with Magnitude defined as a Function, from the selected Base
Analysis.

Restart Workflow Example

Below is one of the typical workflows that the Restart Analysis Add-on is used for. Here, a Bolt Pretension
load (2 load steps—Bolt load + Bolt lock) is present in the Base Analysis. In the restarted system (i.e.,
B5), the Base Analysis is restarted, and Force and Pressure loads are applied in Load step 3.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
210 of ANSYS, Inc. and its subsidiaries and affiliates.
Restart Analysis System Criteria
The criteria below must be met for the Restart Analysis. If you use Create Restart Analysis to create
the Restart Analysis directly, all the criteria are automatically satisfied. If you use the Restart Setup
object and all the criteria are not met, warning messages are issued, and the Restart Setup object will
be invalidated.

• As the Restart Analysis continues from the Base Analysis, more steps (load steps) are required in the
Restart Analysis compared to the Base Analysis.

• For Static-Static restarts, the Base and Restart Analyses must have identical Large Deflection, Newton
Raphson, Solver Type, and Quasi-Static settings under Analysis Settings.

• For Transient-Transient restarts, in addition to the preceding criteria, Application Based Settings and
Damping Controls must be identical between the Base and Restart Analyses.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 211
Restart Analysis Add-on

• The step end times and substep settings (of the Base Analysis) are retained in the Restart Analysis.

• Weak springs are not permitted in the Restart Analysis.

• If the Base Analysis is not solved, the Solver Unit System setting (under Analysis Settings) is the
same for the Base and Restart Analyses. If the Base Analysis is solved, the Solver Unit System setting
for the Restart Analysis is the same as the unit system in which the Base Analysis is solved (irrespective
of the active unit system in Mechanical).

• Contact Split is not permitted in the Restart Analysis.

General Limitations
• This Add-on is available for connected Static-Static or Transient-Transient Structural Analysis only.
That is, they share the mesh and appear within the same Mechanical window.

• It is compatible with the Windows operating system only.

• HPC Platform Services (HPS) and Multistage Cyclic Symmetry are not supported by the Restart Ana-
lysis Add-on.

• When the Only Restarted Steps (Default) option is used during post-processing and you attempt
to retrieve the result at a time point corresponding to the Base Analysis steps, the result corresponding
to the nearest available time point in the solved model is displayed.

• When a Modal analysis is restarted from Load Step 2 or higher, it does not activate certain elements
in the presence of Element Birth and Death or Contact Step control in the pre-stress Static Structural
analysis.

• If Retain Files After Full Solve under Analysis Settings of the Restart Analysis is set to Yes, set
Combine Restart Files to Yes.

• If inertial loads (Standard Earth Gravity, Acceleration, Rotational Acceleration, and Rotational Velocity)
are present in the Base Analysis, they must also be added to the Restart Analysis. To add them, drag
and drop all the inertial loads from the Base Analysis onto the Restart Analysis.

Limitations for Loads and Boundary Conditions

Any loads and boundary conditions that create new elements are not permitted during the restart, as
new elements cannot be created in a Restart Analysis. However, all loads and boundary conditions applied
in the Base Analysis are still active by default in the Restart Analysis. Consider these limitations:

• Force, Pressure, Imported Pressure, or Hydrostatic Pressure loads are permitted only with the Applied
By option set to Direct, unless a Nonlinear Adaptive Region is defined in the Base Analysis. However,
using the Load Applied by Surface Effect (Restart) option modifies the existing surface-based Force
or Pressure loads in the Base Analysis.

• Force loads scoped to vertices are not permitted. As an alternative, use Nodal Force to apply Force
loads on a nodal-named selection.

• Remote loads (Remote Force, Remote Displacement, and Moments) are permitted only with the Remote
Point scoping method.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
212 of ANSYS, Inc. and its subsidiaries and affiliates.
• Elastic Support, Compression Only Support, Bearing Load, Nodal Orientations, Imported Initial Stress
or Strains, and Line Pressure objects are not permitted in the Restart Analysis.

• Modifying Bolt Pretension loads in the Restart Analysis is not supported. For evaluating Bolt results
using the Bolt Tool, drag and drop the Bolt Pretension loads from the Base Analysis onto the Restart
Analysis. Do not change the Scoping or Formulation of the Bolt Pretension objects. The Define By
property will be set to Open for clarity.

• Nonlinear Adaptive Regions are permitted in the Base Analysis only. However by default (the Time
Range property set to Entire Load Step), a Nonlinear Adaptive Region is active for all the load steps
in the Base and Restart Analyses. To make a Nonlinear Adaptive Region active for specific load steps
only (for instance, activating it for the Base Analysis only), use the Time Range property.

If a Nonlinear Adaptive Region is present in the Base Analysis:

– Imported loads are not permitted in the restarted analysis.

– Nodal Force, Nodal Pressure, and Nodal Displacement objects are not permitted in the Restart
Analysis, if the scoping belongs to the bodies scoped in the Nonlinear Adaptive Region objects
in the Base Analysis.

– Only the Base + Restarted Steps (Full Time History) option is permitted.

– If the Time Range of the Nonlinear Adaptive Region objects in the Base Analysis is set such
that remeshing is also active in the Restart Analysis, Element Birth and Death or Contact Step
Control objects are not permitted in the Restart Analysis.

• Element Birth and Death and Contact Step Control are permitted in the Base and Restart Analyses,
unless Contact Split is active in the Base Analysis.

Note:

Do not set the status (under Step Controls) for either Element Birth and Death or Contact
Step Control objects to Dead, if the load step number is less than or equal to the Restart
load step number (in the Restart Setup object). This is an interface limitation that has no
effect on the solution. The Status setting is only considered for a load step number
greater than the Restart load step number.

Restrictions on Displacements
If a Nonlinear Adaptive Region is present in the Base Analysis, displacements are permitted with the
following restrictions:

• If Displacement boundary conditions (in the Base or Restart Analysis) that are scoped to geometric
entities (vertices, edges, or faces) belonging to the bodies scoped to a Nonlinear Adaptive Region
in the Base Analysis are present, only Named Selection Scoping is permitted.

• Multiple Displacement objects cannot be applied using the same Named Selection.

• Displacement objects cannot be applied in a Restart Analysis alone. If a Displacement is applied

in the Restart Analysis, a corresponding Displacement (using the same Named selection scoping)

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 213
Restart Analysis Add-on

must be applied in the Base Analysis. This also applies to component Displacements (i.e., a
component cannot be Free in the Base Analysis and loaded in the Restart Analysis).

• For Displacements, only Tabular Loading is permitted. In the Details panel of Displacement objects,
only setting Independent Variable as Time is permitted (i.e., step loading or function loading
is not permitted).

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
214 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 8: Hydrodynamic Add-ons
The following Add-ons are available for hydrodynamic analysis:
8.1. Hydrodynamic Pressure
8.2. Offshore
8.3. Aqwa Co-simulation

8.1. Hydrodynamic Pressure

The Hydrodynamic Pressure Add-on allows you to transfer external surface and internal tank pressures,
selected loads and structural accelerations calculated in a Hydrodynamic Diffraction or time domain
Hydrodynamic Response analysis onto panel and beam elements in a Static Structural analysis. This re-
moves the need to create, manipulate and run hydrodynamic load files external to Workbench. For
more information about this Add-on, see The Hydrodynamic Pressure Add-on.

8.2. Offshore
The Offshore Add-on exposes the OCEAN commands in Mechanical APDL, which can be used to include
the hydrodynamic loads on submerged beam and pipe elements – resulting from the motion of the
structure through the fluid, or from the fluid motion around the structure due to current or waves – in
Static Structural, Transient Structural, Modal and Harmonic Response analyses. For more information
about this Add-on, see The Offshore Add-on.

8.3. Aqwa Co-simulation

The Aqwa Co-simulation Add-on combines the Rigid Dynamics and Aqwa solvers to create a more
powerful simulation. For example, this co-simulation system solves marine structures which have complex
contact, shaft, and gear components, such as a point absorber. It also conducts Hydro-Aero-Multi-body
coupling analyses for floating offshore wind turbines. For more information about this Add-on, see The
Aqwa Co-simulation Add-on.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 215
 Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
216 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 9: Additive Manufacturing Add-ons
The following add-ons are available for additive manufacturing analyses:
9.1. LPBF Process
9.2. DED Process
9.3. Sintering Process
9.4. Distortion Compensation

9.1. LPBF Process

The LPBF Add-on simplifies the setup of a Laser Powder Bed Fusion process analysis. A wizard steps
you through part and support identification, meshing, materials, process parameters, and boundary
conditions. Completion of the wizard leaves the simulation ready to solve. For more information about
this add-on, see Using the LPBF Setup Wizard.

9.2. DED Process

The DED Process Add-on simplifies the setup for a Directed Energy Deposition (DED) process analysis.
A wizard steps you through part and baseplate identification, meshing, weld path definition, material
parameters, machine settings, build and cooldown conditions, and base removal setup. Upon completion
of the wizard, you will need to generate element clusters, and then solve the simulation. For more in-
formation about this add-on, see Introduction to DED Additive Manufacturing.

9.3. Sintering Process

The Sintering Process Add-on simplifies the setup for a sintering process for a binder-jet manufactured
part. A wizard steps you through part and support identification, meshing, material parameters,
boundary conditions, and recommended solver settings. The add-on adds new load and result objects
that describe the sintering process and underlying state variables. Completion of the wizard leaves the
simulation ready to be solved. For more information about this add-on, see Introduction to Sintering.

9.4. Distortion Compensation

The Distortion Compensation Add-on allows you to compensate for the anticipated distortion that occurs
during a product's manufacture. Specifically, the add-on compensates a geometry so that after loading
or processing, it distorts into the original target geometry. For more information about this add-on, see
Introduction to Distortion Compensation.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 217
 Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
218 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 10: Rigid Dynamics Add-ons
The following Add-ons are available for Rigid Dynamics analyses :
10.1. Variable Load
10.2. Motion Load Transfer

10.1. Variable Load

The Variable Load Add-on greatly simplifies the definition of complex loading for Rigid Dynamics systems.
It allows you to create loads that depend on the state of the model and make them conditionally applied.
For more information about this Add-on, see Using the Variable Load Add-on.

10.2. Motion Load Transfer

The Motion Load Transfer Add-on allows you to apply the loads created in a Rigid Dynamics analysis
on the flexible bodies in a Static Structural analysis. For more information about this Add-on, see Using
the Motion Load Transfer Add-on.

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 219
 Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
220 of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 11: Add-ons Tutorials
The following tutorials are available so you can get better acquainted with the interfaces, features, op-
tions, and settings for specific add-ons.

DesignLife
Fatigue Analysis of a Simple Shaft Under Combined Bending and Torsion

Fatigue Analysis with Base Excitation Acceleration Loading

Fatigue Analysis of Short Fiber Composite Materials

Fatigue Analysis Using Named Selections for Materials Assignment

Additive Manufacturing
Calibration - Double Arches Geometry

LPBF Simulation - Bracket

DED Simulation - Racetrack

Sintering Simulation - Printed Bridge

Turbomachinery
Turbomachinery Mistuning Analysis using the Forced Response Add-on

Turbomachinery Aero Coupling Analysis using the Forced Response Add-on

Multi-harmonic Load Combination Results and Chart

Calculating the Harmonic Indices for a Multistage Analysis

NVH
Modal Assurance Criterion (MAC) Analysis

Characterize the Dynamic Behavior of a Structure using Frequency Response Functions (FRFs)

Optimum Sensor and Exciter Locations for Vibration Tests (Pre-Test Calculator Analysis)

Restart Analysis
Multiple Load Step Restart Using Restart Analysis Add-on

Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 221
 Release 2024 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
222 of ANSYS, Inc. and its subsidiaries and affiliates.