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SIMULIA fe-safe

Durability Analysis Software for Finite Element Models

fe-safe is the technical leader in fatigue analysis software for Finite Element models and is capable of meeting its users’ most demanding applications. It directly interfaces to all leading FEA suites and is used by leading companies in the transport and mobility, aerospace and defense, general manufacturing, power generation, marine and offshore industries worldwide to determine fatigue life and optimize designs. fe-safe is renowned for its accuracy, speed and ease of use.

fe-safe has been developed continuously since the early 1990’s in collaboration with industry to ensure that it continues to set the benchmark for fatigue analysis software. It was the first commercially available software to focus on modern multiaxial strain based fatigue methods and the first to incorporate capabilities for non-metallic materials. fe-safe analyses metals and composite materials, elastomers, thermo-mechanical and creep fatigue and employs the Verity® structural stress method or the fatigue analysis of welded joints – the only commercial software to incorporate this methodology.

fe-safe Software Suite

Regardless of the complexity of your fatigue analysis, fe-safe fits smoothly into your design process, enabling you to develop products that are designed for durability.

fe-safe offers the user an easy-to-use fatigue analysis suite that interfaces with all the leading FEA suites.

With fe-safe as an integrated part of the design process, customers have the ability to:

  • accurately identify fatigue hotspots
  • optimize designs to use less material
  • reduce product recalls and warranty costs
  • validate design and test programs
  • improve correlation between test and analysis within a single user interface
  • reduce prototype test times
  • speed up analysis times, thereby reducing man-time hours
  • increase confidence that your product designs pass their test schedules as “right first time”

Optional Add-Ons

Best-in-class extensions, tailored for complex problems

Silicone rubber finger joint prosthesis


fe-safe/Rubber is the first and only commercially available software tool for the fatigue analysis of rubber and elastomers.

Developers of rubber materials, components and systems increasingly rely on simulation as a routine means to address design issues.

The call for simulation of durability is especially strong and durability often dominates development agendas. For metallic components, solutions for fatigue analysis from FEA have existed commercially for many years and have become an essential part of maturing and qualifying design concepts in many industrial sectors. Now a solution for elastomers is finally available as well.

fe-safe/Rubber is a:

  • Unique, patented solution for the simulation of fatigue failure in elastomers
  • Purpose-developed tool for elastomers, possessing a formidable validation case
  • Developed by Endurica, leaders in the development of elastomer technology


Thermo-mechanical fatigue occurs when both stress and temperature fluctuate.

fe-safe/TMF (thermo-mechanical fatigue) was developed in conjunction with a major engine manufacturer to provide fast and accurate fatigue and durability analysis of structures subjected to fluctuating temperatures and stresses.

fe-safe/TMF is used in conjunction with the standard version of fe-safe and incorporates additional time-dependent thermo-mechanical fatigue mechanisms. The analysis uses stress and temperature results from elastic Finite Element analysis. All the standard capabilities of fe-safe, such as critical plane multiaxial fatigue and analysis of cast irons, are included.

Incorporates strain rate, phase relationship, pre-soaking, and bulk stress relaxation

Thermo-mechanical fatigue in piston


Safe Technology has partnered with Wolf Star Technologies, experts in loading calculation and FEA model correlation, to provide a unique and advanced solution for accurate in-situ load measurement.

Historically, predicting fatigue life has been challenging because even simple structures undergo complex loading. Many engineering organizations rely on historical data or multi-body dynamics models for loading profiles, often without correlation to the FEA model.

The accuracy of the fatigue prediction is directly related to the accuracy of the loading profile and position of the strain gauges. Uncorrelated loading profiles will lead to incorrect fatigue calculations. Even small errors in loading knowledge can lead to large errors in fatigue life prediction because of the log-log nature of fatigue life models.

With fe-safe/True-Load the unknowns in loading are eliminated.


How does elevated temperature service reduce durability? What is the cause of failure – creep, fatigue, or creep-fatigue interaction? fe-safe/TURBOlife has the answers.

fe-safe/TURBOlife creep-fatigue algorithms have been successfully applied to nuclear power plant components, power station boilers, gas turbine blades and steam turbine components. fe-safe/TURBOlife is used increasingly in the powertrain industry where creep and creep fatigue interaction is prevalent in automotive exhaust components and turbocharger impellers.


  • Consider complex and interacting damage mechanisms induced by creep and fatigue conditions
  • Identify whether the damage is predominantly fatigue, creep or creep-fatigue interaction
  • Allow for damage computations using ductility exhaustion with creep fatigue interaction or strain range partitioning


safe4fatigue is an integrated system for managing durability analysis. It provides advanced multiaxial fatigue and durability analysis from measured or simulated strain signals, peak-valley files, cycle histograms and PSDs.

safe4fatigue is available as a stand-alone product where signal processing only is required, and it is included in fe-safe as a no-cost module. Its development has been driven by the requirements of Safe Technology’s consultancy projects, to provide all the capabilities needed to analyse practical durability applications without the overhead of complex ‘management’ systems. Its attractive, easy-to-use user interface provides fast access to complex analysis procedures. Repetitive tasks can be automated using powerful macro-recording and batch processing.

Regardless of the complexity of your fatigue analysis, safe4fatigue fits smoothly into your design process, enabling you to develop products that are designed for durability.

Verity in fe-safe

For welded joints and welded structures, including spot welds, the prediction of failure locations and the calculation of fatigue lives have traditionally been notoriously complex and difficult tasks that can often result in poor correlation with test data.

The Verity mesh-insensitive Structural Stress Method has been developed and patented by Battelle. It is recognised as a major breakthrough in the fatigue analysis of welded joints for Finite Element models.

“A Bolt of Genius in Welding”, Business Week (2004)

Verity in fe-safe combines Verity for the fatigue of welded structures with the advanced features of fe-safe for fatigue analysis for finite element models. It allows companies to reduce or avoid the expense of testing to validate the integrity of designs and avoid the common practice of over-engineering due to the uncertainty of fatigue life.

Data Sheets

SIMULIA fe-safe Data Sheet


fe-safe Brochure
fe-safe Industry Applications

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