Misutech-HBK Interface Links Machining and Fatigue Analysis

Fatigue analysis Misutech and HBK launch integrated simulation solution

2026-03-09 Source: HBK 1 min Reading Time

Misutech and HBK have introduced a new interface linking Misutech’s Misulab machining simulation software with HBK’s nCode DesignLife fatigue analysis solution. The combined workflow enables engineers to evaluate machining strategies, assess the fatigue impact of new tools or process parameters, and optimise production conditions more efficiently.

Through the interface between Misulab and nCode DesignLife, Misutech and HBK are now able to jointly support their customers in increasing production competitiveness while reducing the risk of premature failures of critical parts. (Source: HBK) — Through the interface between Misulab and nCode DesignLife, Misutech and HBK are now able to jointly support their customers in increasing production competitiveness while reducing the risk of premature failures of critical parts.
(Source: HBK)

Machining processes can subject materials to extreme plastic deformation and sharp temperature rises within milliseconds, altering surface integrity through residual stresses, strain hardening, and microstructural changes. These factors strongly influence fatigue life but have traditionally been difficult to incorporate into fatigue calculations, making it challenging to optimise machining without increasing the risk of premature component failure.

The new interface overcomes this limitation by allowing Misulab’s predicted residual stress fields—resulting from machining—to be transferred directly into nCode DesignLife along with mechanical loading data. This integration enables fatigue assessments that account for both manufacturing-induced and operational stresses, providing a more complete picture of component behaviour.

According to the companies, the solution reduces the need for costly physical trials and long-duration fatigue tests. In one example involving an aerospace transmission shaft, machining conditions optimised through the new workflow eliminated harmful residual stresses and delivered a marked improvement in fatigue performance compared with standard turning processes.

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