マグナ・インターナショナル・ジャパン List of Products and Services

"FEMFAT MELCOM" is a software package developed by Magna Powertrain Engineering Center Steyr (ECS) to predict defects on printed circuit boards (PCBs) incorporated in power electronics products such as inverters through simulation. 【Features】 ■ Predicts cracks in solder joints on printed circuit board assemblies (PCBAs) due to vibrations in power electronics products. ■ Predicts flex cracks in multilayer ceramic capacitors (MLCCs) during the process of attaching PCBAs to power modules. ■ Predicts cracks due to thermal fatigue in response to temperature loads on PCBAs. *For more details, please download the PDF or contact us.

"FEMFAT" is a leading software for fatigue life prediction that performs fatigue analysis in combination with general finite element programs. With interfaces for multi-body simulation, optimization, and measurement systems, it allows for complete and convenient integration into the CAE process, providing optimal solutions for all customers through flexible licensing options. With over 30 years of continuous development, FEMFAT has refined fatigue analysis methods and gained a reputation for excellent fatigue evaluation, earning the trust of engineers worldwide. It contributes to improving the reliability of various industrial products, not only in the automotive industry but also in industrial machinery and plant equipment. Developed by engineers for engineers, FEMFAT offers advanced features and analysis options for predicting the fatigue life of metallic and non-metallic products, including seam welds and spot welds. It enables various analyses, such as those involving base materials with welds, spot welds, multi-axial analysis using road load data, and probabilistic loads based on PSD. *For more details, please download the PDF or contact us.*

"FEMFAT LAB" is a powerful measurement data processing software that enables the visualization and analysis of vast amounts of data, serving as a standard tool across experimental, measurement, and development departments. It is equipped with features that allow for the instantaneous analysis of hundreds of channels and millions of time series data, as well as the automatic or manual removal of outlier drift values, shifts in average values, and spike values. In addition to selling the software mentioned above, we also offer contract services utilizing our software. Please feel free to contact us if you have any requests. 【Features】 ■ User-friendly for visualizing/analyzing large amounts of data ■ Supports various file format binary data, allowing data analysis without conversion ■ Achieves excellent convergence of iterations between measurement results and simulation results ■ Software capable of calculating time series vibration input data, etc. *For more details, please download the PDF or contact us.

"MAMBA" is a mode-based contact analysis software that can effectively and accurately consider contact nonlinearity in static and dynamic simulations within multi-body simulation (MBS). It can be introduced without changing the existing analysis process if dynamic analysis using MBS has already been conducted. In addition to selling the above software, we also offer contract services utilizing our software. Please feel free to contact us if you have any requests. 【Features】 ■ Nonlinear contact analysis of elastic structures using MBS ■ Addition of contact modes to the mode synthesis method ■ Automatic detection of contact surfaces and automatic calculation of necessary contact modes ■ Dramatic improvement in result quality is expected in dynamic analysis of structures with joints that include contact ■ Faster computation time compared to contact analysis using nonlinear FEM, etc. *For more details, please download the PDF or contact us.

When evaluating the fatigue strength of a set of stress amplitudes, mean stress, and constant stress, FEMFAT basic is an ideal tool. With FEMFAT basic, you can calculate the fatigue life or fatigue limit safety factor of components subjected to repeated or alternating loads. It simultaneously considers various influencing factors on fatigue and analyzes joining structures such as seam welding and spot welding along with the base material, allowing for appropriate fatigue life predictions to be obtained concurrently. It comes standard with a database of over 400 materials. Additionally, when creating new material data, you can use the "Material Generator" to create the necessary material data set for FEMFAT even from limited material strength data. *For more details, please download the PDF or contact us.*

EMFAT plast calculates the elastic-plastic stress around the notch area based on the results of linear elastic analysis using the Neuber correction. The Neuber rule is a method that demonstrates the relationship between linear and nonlinear stress and strain, allowing the representation of the Neuber hyperbola using Young's modulus E and nonlinear strain εplast. To represent the hysteresis loop of the cyclic stress-strain diagram (using the cyclic hardening coefficient K' and cyclic hardening exponent n'), the Ramberg-Osgood rule is used to calculate the nonlinear stress as the intersection point with the Neuber hyperbola. This eliminates the need for FE analysis considering material nonlinearity for local plasticity, allowing the elastic-plastic stress to be corrected with FEMFAT plast. Additionally, FEMFAT plast enables a reduction in computational effort for FE analysis. FEMFAT plast is compatible with FEMFAT basic, FEMFAT max, and FEMFAT spectral. *For more details, please download the PDF or contact us.*

Predicting fatigue life under multi-axial loading is one of the significant challenges. The approach applied in FEMFAT max is based on research results conducted in collaboration with international research institutions, as well as the latest development achievements and academic papers within the company. All methods, theories, and hypotheses have been utilized in various projects and have been successfully validated. FEMFAT max includes ChannelMAX and TransMAX based on loading conditions, evaluating damage or fatigue life, fatigue limit safety factors, static fracture safety factors, and multi-axiality at each FE node. 【Module Introduction】 - Accurate fatigue strength assessment under actual loading conditions - Interface for time history data compatible with general-purpose mechanism analysis software and measurement software (e.g., ADAMS, RPC, DIAdem) - Input of loads corresponding to superposition (Channel) and transient response (Transient) - Filtering function for quick calculations only at necessary locations - Safety factors and damage calculations for fatigue limits under multi-axial stress states *For more details, please download the PDF or contact us.

To ensure the structural strength of passenger car and truck cabins, numerous spot welds and punch rivets are required. Each of these joints implies the potential for initial cracks, necessitating particularly reliable methods for fatigue strength analysis. FEMFAT spot provides an evaluation method for accurately simulating the stiffness and durability strength of thin sheet metal components composed of spot welds. FEMFAT spot offers two different approaches: ◆ A method using element stresses from shell elements ◆ A method using element forces from connection elements (JSAE method) *For more details, please download the PDF or contact us.

In the development of components that include welded structures, accurately predicting the fatigue life of weld joints has become essential. By utilizing FEMFAT weld, precise fatigue life predictions for weld joints can be achieved. FEMFAT weld offers various functions, including sensitivity analysis to identify critical welding shape parameters and evaluation options compliant with standards such as BS7608 and Eurocode 3. When calculating the fatigue life and safety factors of welded structures, the highly flexible analytical methods implemented in FEMFAT weld allow for simultaneous analysis of shell element models and solid element models. For the evaluation of weld root areas and weld termination points, detailed modeling of the fillet shape of the evaluation area can be performed, eliminating the need for extensive manual work. *For more details, please download the PDF or contact us.*

In highly random excitation mechanisms (such as vibrations caused by bench tests or road surface inputs), analyzing vast amounts of time series data requires significant computational costs. FEMFAT spectral provides the optimal solution to this challenge. By directly performing damage calculations from multi-axis time series inputs in the frequency domain (random response fatigue), it can significantly reduce the computation time for fatigue life analysis. To achieve this, FEMFAT spectral transforms data into the frequency domain known as PSD (Power Spectral Density). This allows for damage calculations under multi-axis loading conditions to be executed directly in the frequency domain. In many application cases, the excitation loads are not completely independent. Therefore, FEMFAT spectral offers the option to consider the correlation between individual excitation loads by defining the cross power spectral density (cross PSD). Utilizing cross PSD provides an additional advantage by allowing the equivalent stress PSD to be statistically formed correctly. *For more details, please download the PDF or contact us.*

FEMFAT laminate is a module for fatigue analysis of continuous fiber reinforced resins (available in ChannelMAX). Within the MAX module, fatigue strength evaluation can be conducted individually for each laminate. The front and back sides of each laminate in the composite material are subject to damage calculation. The analysis method is adapted to the laminate material using the stress types of "Critical Component in Critical Plane," evaluating fiber breakage and interlayer breakage within the fibers. Furthermore, when using a solid element model (typically 8-node hexahedral elements), delamination can also be assessed. For damage calculation, static strength characteristics (tensile strength and compressive strength) and fatigue strength characteristics (S-N curves) are required for loads in the parallel and perpendicular directions to the fibers, as well as for shear loads in the laminate plane. It supports shell and solid elements defined with COMPOSITE properties using Abaqus inp files and odb files. *For more details, please download the PDF or contact us.*

The FEMFAT visualizer is a lightweight 3D post-processor with an independent interface from other modules, capable of displaying the analysis results of FEMFAT and stress values from FE analysis. Furthermore, by using the FEMFAT visualizer, it is easy to define seam welds necessary for FEMFAT weld calculations in shell element models. The FEMFAT visualizer allows for the display of FEMFAT calculation results such as damage, fatigue life, and fatigue limit safety factors, as well as the creation of report materials. Additionally, by adding output options, it provides information that helps in gaining a deeper understanding of the analysis results. This information includes all parameters related to FEMFAT analysis (currently over 50 types). For example, it is possible to check the effects of equivalent stress amplitude, equivalent mean stress, or the influence factors related to fatigue used in the analysis on the local S-N curve. *For more details, please download the PDF or contact us.*

FEMFAT break is the only module within FEMFAT that is not used for analyzing fatigue strength. It is an extended module that calculates the safety factor against "fracture or yielding" of structural components that undergo local plastic deformation and fracture or yield. FEMFAT break can be integrated with FEMFAT basic or FEMFAT max. *For more details, please download the PDF or contact us.*

Thermal-mechanical fatigue (TMF) analysis refers to the fatigue life prediction analysis targeting the combination of thermal and mechanical loads. TMF analysis is one of the most challenging tasks in the field of fatigue analysis. By introducing FEMFAT heat, this challenge can be addressed. The purpose of TMF analysis is to calculate the damage to components subjected to mechanical loads. It applies to parts exposed to high-temperature thermal fluctuations, such as turbochargers, cylinder heads, and exhaust manifolds. FEMFAT heat is based on an evaluation method demonstrated by Dr. Sehitoglu (University of Illinois, USA) and utilizes not only time-series temperature distribution data from finite element analysis (FEA) but also employs elastic-plastic stress and strain in fatigue life predictions. The characteristics of this evaluation method consider three mechanisms related to TMF damage: - Thermomechanical damage - Damage due to oxidation - Damage due to creep The FEMFAT material database used in FEMFAT heat is expanded compared to the commonly used material database for evaluating (high-cycle) fatigue life.

By using this module, you can calculate the fatigue limit safety factor and damage based on measured strain data, and you can also compare the measured strain data with simulated strain data. FEMFAT strain links the results of bench tests and simulations. Using this module allows for fatigue life predictions for specific areas based on measured strain data. Therefore, it is not necessary to perform FE analysis (STRAIN calc). The second option can be used for calibrating the FE model. It is possible to compare the stress values measured on actual components with the values from the simulation results (STRAIN comp). FEMFAT strain is available as an additional result output (STRAIN comp) for FEMFAT basic and FEMFAT max. Additionally, STRAIN calc is a separate independent module. *For more details, please download the PDF or contact us.

This is a token-based extension module that enables the use of multiple CPUs installed in a workstation to accelerate the analysis time of FEMFAT. By using this module, FEMFAT analysis jobs can be automatically divided into multiple jobs, which can be executed simultaneously. In this parallel computation, the job's analysis group is divided into a specified number of subgroups of approximately equal size, and FEMFAT is launched for each of these subgroups. The computation results from all analysis jobs (.fps files) are ultimately consolidated into one. For parallel computation of fatigue analysis, either parallel tokens or standard licenses are used. *For more details, please download the PDF or contact us.*

Acoustic requirements of automotive components have increased in importance over the recent years due to legal regulations, lightweight design, higher customer demands and especially due to the introduction of electrical vehicles with lower masking noises and high tonal noise content. MNOISE supports the simulation engineer at the acoustic evaluation of components based on Finite Element (FE) simulations. In combination with common FE tools, it enables an acoustic evaluation even in an early concept design phase. Especially global dynamic characteristics of components are responsible for the acoustic performance. Those only can be influenced significantly in an early concept phase. Using MNOISE critical areas and acoustic hotspots can be detected on the virtual component by evaluating acoustic near field measures. Based on these results, design improvements can be done before a physical prototype is available. Development time and prototyping costs can be reduced. *For more details, please download the PDF or contact us.*