IWSD M3_3 -Introduction to the Design of Structures
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Transcript of IWSD M3_3 -Introduction to the Design of Structures
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Objective: The objective is to provide an introduction to the philosophy and process of design for welded structures.
Module 3.3: Intoduction to the design of structures
1
Scope: Design goals and constraints, Safety, economy, durability and serviceability, Proportioning of members, Analysis and evaluation, Partial safety factors, Sources of variation in design loads and strength of structural components, Ultimate and serviceability limit states
Expected result: Clarify the set of design objectives that are placed on a structure. Illustrate the design process first concept to detail design and final evaluation. Introduce the concepts of optimization with respect to performance, manufacturability, life cycle cost, etc. Demonstrate the set of limit states that are placed on a structural system. Illustrate the possible influences of manufacturing tolerances on the final design of a structure. Explain the basic aspects of limit state design. Illustrate the use of partial safety factors in calculations. Compute loading combinations required in limit state design method. Explain sources of load variation for welded structures.
IWSD M3.3
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2 IWSD M3.3
Design of welded structures
Structural design may be defined as a mixture of art and
science, combining the experienced engineer’s intuitive feeling
for the behaviour of a structure with a sound knowledge of the
principals of statics, dynamics, mechanics of materials and
structural analysis, to produce a safe economical structure that
will serve its intended purpose
Salmon and Johnson
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3 IWSD M3.3
Basic loadings
P
P
P
P
P
Mv
Tensile loading
Compressive loading
Shear loading
Bending
Torsional loading
Mv
Multiaxial loading
P
Different types of loading
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4 IWSD M3.3
Structural materials
Real behavior of material, e.g. S355 Idealized for design
Stress-strain relation in structural steel
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5 IWSD M3.3
Structural materials
I-Beam subjected to bending – elastic plastic deformation
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6 IWSD M3.3
Structural materials
Plate with hole – stress concentration
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7 IWSD M3.3
Structural materials
Materials have properties but not shapes – when we assemble the material into structural members with shape
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8 IWSD M3.3
Structural materials
Common welded shapes
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9 IWSD M3.3
Design of structures
Classification of structural members – based on function
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10 IWSD M3.3
Design of structures
Behaviour of a structure depends on how loads are transfered between members
truss structures beam structures plate structures frame structures
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11 IWSD M3.3
Type of structural steel sections
Hot rolled sections
W (a) Wide-flange Shape
S (b) American Standard
Beam
C (c) American Standard Channel
L (d) Angle
WT or ST (e) Structural
Tee
(f) Pipe Section
(g) Structural Tubing
(h) Bars (i) Plates
a – Wide-flange : W 18 97
b – Standard (I) : S 12 35
c – Channel : C 9 20
d – Angles : L 6 4
e – Structural Tee : WT, MT or ST e.g. ST 8 76
f & g – Hollow Structural Sections HSS : 9 or 8 8
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12 IWSD M3.3
Type of structural steel sections
Cold formed sections
(a) Channels (b) Zees (c) I-shaped double channels
(d) Angles (e) Hat sections
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13 IWSD M3.3
Type of structural steel sections
Build up sections
Built-up (W) shapes.
Built-up (C) Channels.
Built-up (L) Angles.
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14 IWSD M3.3
Type of structural steel sections
Tension members
(a) Round and rectangular bars, including eye bars and upset bars.
(b) Cables composed of many small wires.
(c) Single and double angles.
(d) Rolled W – and S – sections.
(e) Structural tee.
(f) Build-up box sections.
Perforated plates
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15 IWSD M3.3
Type of structural steel sections
Compression members
(a) Rolled W-and S- sections.
(c) Structural tee.
(b) Double angles.
(e) Pipe section
(d) Structural tubing
(f) Built-up section
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16 IWSD M3.3
Type of structural steel sections
Bending members
(a) Rolled W-and other I-shaped sections.
(c) open web joist. (b) Build-up Sections.
(f) Built-up members (d) Angle (e) Channel (g) Composite steel-Concrete
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17 IWSD M3.3
The design process – simplified
System Desired
result Primary effect
Undesired result Secondary effect
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18 IWSD M3.3
Structural design
It is a mixture of art and science to produce a safe and
economical structure that serves its intended purpose
Design is an optimization process
• Min. Weight.
• Min. Cost.
• Min Construction Time.
• Min. Labor Force.
• Min. Operational Cost.
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19 IWSD M3.3
Design process – Iterative cycle
1. Planning, Function Design.
2. Preliminary Structural Configuration.
3. Establish Load Cases & Load Combinations.
4. Preliminary Member Selection.
5. Structural Analysis.
6. Evaluation of all members to meet strength and
serviceability Criteria.
7: Redesign by going to step “3” above. 8: Final Design thus optimum design is achieved.
No
Yes
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20 IWSD M3.3
Design of structures
Sufficient strength Sufficient shape stability Corrossion resistance Seviceability friendly Estetic appealing Sheapest manufacturing processes Low energy consumption Recycleable produkt Welding also requires special aspects aslo:
Strength of joints Material knowledge Manufacturing Quality and Cost
Requirements and goals
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21 IWSD M3.3
Strength of materials
General for welded structures- things needed to be checked
Static loads / Max loads – A welded joint have very good resistance against static loads Fatigue / dynamic loads – Welded joints reduces the fatigue strength considerably!
Open thin-walled structures – Quite often used in welded structures, very sensitive to torsion and buckling
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22 IWSD M3.3
Strength of materials
General for welded structures- things needed to be checked
Instability (column and plate buckling) – Due to welding large compressive residual stresses could be present in the structure Analysis methods
Load conditions Handbook calculations FE Analysis Fracture mechanics
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23 IWSD M3.3
Design principals
Categoty of welded joints based on thier functionality
• Unloaded welded joints
• Static loaded welded joints
• Fatigue loaded welded joints
”Rule of thumb”
If the stress range is < 25 MPa unloaded weld
If number of cycles < 103 static loaded weld
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24 IWSD M3.3
Quality and Cost
What can we gain by choosing a large penetration depth instead of a large outer throat thickness (a-measure) in a fillet weld?
How much is it worth to design welds so that the number of weld beads can be kept down?
Post weld improvement (Grinding, TIG remelting, UIT, etc..) – When does it pay of?
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25 IWSD M3.3
Quality and Cost
When does it pay of by increasing the strength of the base material? What does a higher weld quality cost ? What effect does it have on my structure ? How large deformations due to welding is acceptable? Tolerances?
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26 IWSD M3.3
What is a high quality weld ?
Dshs
Standard welds
Fatigue life
100
High quality welds
120
Geometry improvement
Mechanical improvement
150 140
Fatigue controlled by
•weld angle
•weld toe radius
•size of undercut/cold lap
•throat thickness
•penetration
a
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27 IWSD M3.3
Quality and Cost
Cost for a fillet weld ~ (throat thickness)2
Momentary increase in cost when a weld line is not sufficient
In manual welding, this happens when a = 4-5 mm
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28 IWSD M3.3
Quality and Cost
Rule of thumb: 1 mm more penetration corresponds to 2 mm less throat thickness (a-measure), for a fatigue loaded fillet welds
Lines of constant life in weldroot
of a load carrying cruciform joint
[ compare old rule 2*a worth 1*i ]
0
1
2
3
4
5
0 1 2 3 4 5 6 7 8 9 10
THROAT SIZE, a (mm)
PE
NE
TR
AT
ION
(m
m)
t=10
t=15
t=20
i = 2a
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29 IWSD M3.3
Quality and Cost
Post weld improvement techniques increases the fatigue strength of welded joints
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30 IWSD M3.3
Quality and Cost
Post weld improvement techniques Future investigation
Current situation for
improved joints in
design codes
Improved welded
high strength steels
As welded No effect of UTS
on fatigue strength
of as-welded joints
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31 IWSD M3.3
Quality and Cost
New Volvo weld quality standard for fatigue loaded and statically loaded welded structures
3 types of quality requirements
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32 IWSD M3.3
Quality and Cost
One step higher weld quality 2 times longer fatigue life OR
1One step higher weld quality 25% higher allowable stress
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33 IWSD M3.3
Quality and Cost
Methods to ensure the welding quality of STD Volvo
Improvement techniques to ensure higher weld quality
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34 IWSD M3.3
Material selection
What does the choice of a high strength material? Profit? What qualities besides strength is important for material selection?
Impact toughness Elasticity modulus Strength at high temperatures Thermal expansion Heat capacity
Tensile strength in the thickness direction Z-steel? Base material fatigue strength
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35 IWSD M3.3
Material selection
Weight saving with high-strength materials
Z-steel to avoid lamellar tearing
For cruciform, T and corner fillet welds with full penetration of the weld
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36 IWSD M3.3
Manufacturing aspects
Where is the product manufactured? Own production? Special requirements? (ex Puhra)
What equipment is available? Bending Machines, Cutting / cutting machines, welding equipment, etc. .. Special requirements in robotic welding. Space requirements, seam tracking, location, tolerances, deformation stability, etc. ..
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37 IWSD M3.3
Manufacturing aspects
Smallest possible variation of the dimensions. Standardization. Warehousing Optimizing throat thickness of fillet welds. A too large throat thickness costs much.
Do not confuse the material qualities of the same manufacturer. Be aware of which material is ordered!
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38 IWSD M3.3
Basic requirements of structures (Eurocode)
A structure shall be sized and designed to provide adequate Load resistance Serviceability
When a fire resistance should be sufficient for the time required
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39 IWSD M3.3
Basic requirements of structures (Eurocode)
A grid system shall be sized and designed so that it is not damaged by accidents such as
Explosion Collision The effect of human error
In a scope not proportional to cause
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40 IWSD M3.3
Requirements for Robustness
A robust structure or system shall be designed so that its sensitivity to accidental actions minimized Avoid, eliminate and reduce the risk of accidents. Example:
Put up barriers to protect the impacting vehicle Do not explosive details (eg, fuel tanks, gas lines) inside the bearing elements Set up quality measurement systems - QMS
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41 IWSD M3.3
Requirements for Robustness
Choose type of structure which is less sensitive to the current risks of accident Example: Follow the guidelines in Eurocodes EN 1992 – EN 1996 Continuous structural members (vertically and horizontally) Proportion of structural detais (eg continues plate instead of dubble fillet welds in tensile loaded crossing plates) Are there alternatives paths for the forces if load-bearing structural elements are removed?
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42 IWSD M3.3
Requirements for Robustness
Choose a structural element which can sustain (redundant system) A collapse of a single structural detail or A collapse of a limited part of the structure or The onset of a limited local damage
If there are structural elements as if they would collapse would mean accident consequence is excessive, these elements are termed Key Elements
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43 IWSD M3.3
Requirements for Robustness
Avoid load carrying parts that can collapse without previous warning
Attempts to design so that the structure has major visible deformation or cracks before collapse Connect the structural elements to each other
If a part collapses, adjacent parts takes the load; redundancy
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44 IWSD M3.3
Limit state (gränstillstånd)
Distinguish between: Ultimate limit state (brottgränstillstånd)
Serviceability limit state (brukgränstillstånd)
Ultimate limit state considers
• Human safety • Structural safety
Conditions just before the structure collapse is studied
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45 IWSD M3.3
Ultimate limit state
Following conditions should be verified: Loss of equilibrium of the structure or part of the structure Failure due to large deformation1), the structure becomes a mechanism or material failure
Failure caused by fatigue or other time-dependent effect 1) Failure due to mechanical instability
Different partial safety factors for the different conditions
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46 IWSD M3.3
Seviceability limit state
It is considered when: human well-being Structural functionality The structural appearance1)
1) Large deflection, visable cracks
• Distinguish between Reversible and Non Reversible Serviceability
limit states
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47 IWSD M3.3
Seviceability limit state
NON REVERSIBLE
REVERSIBLE
Deformation
Time
Deformation
Time
Limit value
First pass
Limit value
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48 IWSD M3.3
Seviceability limit state
Deformations affecting • The appearance • Users' wellbeing • Installations feature and function Vibrations and oscillations which • Cause discomfort to people • Limits structural fuction and operation • Other damage that will eventually affect
• The appearance • The resistance • The structures functionality
Criteria's for verification
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49 IWSD M3.3
Limit state design
Structure and load models shall be based on the two states Verification that no limit state is exceeded when the current design values used in these models
Loads Material properties Product features Geometrical quantities
Verification shall be performed for all relevant design situations and load cases
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50 IWSD M3.3
Limit state design
The requirements should be met by the partial safety factor method
Different design situations and critical load cases are identified Possible deviations from the assumed loading direction and loading modes shall be considered Structure and load models can be either physical or mathematical models
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51 IWSD M3.3
Limit state design
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52 IWSD M3.3
Limit state design
Partial safety factor – a factor applied to characteristic load, strength, etc. to take into account the risk of exceeding the characteristic value and the consequence of exceeding that value.
Note: partial safety factors do not take in to account normal variations in load, strength, etc.
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Partial safety factor for the material
Resistance factor, γm (depends on material values, tolerances, etc)
Considers random deviations in dimensions and material properties and uncertanities in the calculation procedure
If tolerances variation is small and less than 6 % of the avarage value:
γm = 1,0
Otherwise: γm = 1,1
For fatigue: γm = 1,1
Structural safety
IWSD M3.3 53
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Partial safety factor for the load
Load factor, γf ( depends on how well the load is known)
Risk for the load to exceed the characteristic vaule
Uncertainities in load model
γf = 1.0 – 1.5
Total load consist of several components. Since the different loads can not be estimate with the same precsion different γf for different load types, example:
γf = 1.0 for permanent loads, Gk
γf = 1.3 for largest variable load, Qk
Design load; Ld = 1.0Gk + 1.3Qk
IWSD M3.3 54
Structural safety
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Partial safety factor for the consequence of failure
Consequence of failure factor, γn (safety class)
Used to garantue safety level in the structure
Depends on the consequence of failure
IWSD M3.3
Safety class Consequence of failure γn
1 Less serious 1.0
2 Serious 1.1
3 Very serious 1.2
Consequence of failure differs a factor 10 between each class. For many structures within metal industries a safety class of 1-2 give sufficient safety.
55
Structural safety
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Structural safety
IWSD M3.3
Partial safety factors
Den totala safety factor becomes : Stot = γm *γf *γn
Calculation procedure for static loaded structures
Requirement
56
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Structural safety
IWSD M3.3
The general design condition is: Ld ≤ Bd where Ld is design load and Rd is design resistance
Partial safety factor
γf
Design load
Ld = γf*Lk
Ld ≤ Rd
Resistance
Rk
Partial safety factor
γm *γn
Design resistance
Rd = Rk / γm*γn
Partial safety factors
Load
Lk
57
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Structural safety
IWSD M3.3
Partial safety factors
Design value for load Ld is derived by multiplying the characteristic value of the load, Lk, with a load factor, γf
Ld = γf* Lk
Design value for the resistance (material/strength) Rd is derived by dividing characteristic vaule of the strength , Rk, with safety factor, γm and γn
Rd = Rk / γm*γn
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59 IWSD M3.3
Relative and absolute design
Relativ design – Start from an existing design and proportioning the parts in relation to the properties of materials
Absolute design – A new calculation of the entire structure is made with current load conditions and control is done with permissible stresses or deformations
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60 IWSD M3.3
Absolute design
Benefits • The ability to optimize the overall structure • Better sense of the design Disadvantages • Demanding Job effort • Often lacking reliable data on actual loads on the structure
Relative design
Benefits • Easy to perform • Experience from existing design Disadvantages • Chance to get stuck in habitual design thinking spirit • Risk to misjudge the effect of e.g. a thickness change at risk of
instability, fatigue
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61 IWSD M3.3
Relative design
Rule of thumb The plate thickness is inversely proportional to the square root of the yield stress Valid if the plate is subjected to bending For pure axial load applies: Caution at risk of instability / fatigue
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62 IWSD M3.3
Relative design
Change to high-strength steel in tipper basket
ReMS = 235 MPa tMS = 5 mm
ReHS = 700 MPa tHS = ?
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63 IWSD M3.3
Relative design
eHS
eMSMSHS
R
Rtt
t = plate thickness
Re = yield stress
HS = High Strength steel
MS = Mild Strength steel
Rule of thumb
mmt
t
HS
HS
3
700/2355
tMS = 5 mm
ReMS = 235 MPa
ReHS = 700 MPa
eHS
eMSMSHS
R
Rtt
Weight reduction by 40 % and the same resistance! Control for buckling, fatigue and deformations is required!
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Bending example: Lightweight design of a mobile crane
64
w
h
t Governing equations from beam theory
L
P
σmax
D
EI
LP
3
3D
I
eLP maxmax
s
deflection
bending stress
bending stiffness IE
26
2 whhtI moment of inertia
IWSD M3.3
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Bending example: Lightweight design of a mobile crane
65
w
h
t
26
2 whhtI
w x h x t 60x100x10
Weight = 1
Stiffness = 1 Deflection = 1
60x100x6
Weight = 0.61
Stiffness = 0.67 Deflection = 1.49
40x140x5
Weight = 0.61
Stiffness = 1.11 Deflection = 0.9
Reducing weight Increasing stiffness Reducing deformation
stifnessbendingIE
Lightweight Structure
IWSD M3.3
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Bending example: Lightweight design of a mobile crane
66
What do we need to design against?
ratiosslendernesplatet
h
Design against Failure
Plasticity
Yield stress (σyield)
Material dependent
Plastic collapse
Elastic instability
Buckilng stress (σcrit< σyield)
Material independent (??)
Buckling Post buckling collapse
Lightweight structure
L
P Increasing plate slenderness ratio
IWSD M3.3
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67 IWSD M3.3
Challenges in Design of welded structures
o Structural performance • Elastic instability – Buckling resistance • Durability – Fatigue resistance and strength • ....
o Material selection for design
o Manufacturing and joining processes
o LCC
o Enviromental impact, etc...
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68 IWSD M3.3
Choosing different force paths
Welding of stiffener to absorb force component P
Deformation effects
Cross section
Beam with cross section change
Stiffener in the transition
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69 IWSD M3.3
Column and plate buckling
Relation between load P and deflection w for compressed column an simple supported plate subjected to compressive load
Ideal column
Column with imperfection
Ideal plate
Plate with initial buckles
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70 IWSD M3.3
Bending loads
Moving material as far away from the neutral axis as possible
Bad Good
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71 IWSD M3.3
Weakness / Stiffness in bending
Make sure that you have enough constraint to minimize the deflection – if that is one design target
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72 IWSD M3.3
Torsion loads / Torsional Stiffness
Open recangular hollow section
Torsional stiff
Torsional weak
Closed recangular hollow section
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73 IWSD M3.3
Torsion loads / Torsional Stiffness
• Transition from open (torsional weak) to closed (stiff) cross-section
• a) Unsuitable for torsion: Open at A and closed at B
• The transition between the weak and the stiff beam cross sections is too sudden and give rise to stress concentrations
a
b
c
Bad
Better
Good
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74 IWSD M3.3
Load paths
Important to design load entries correctly; Se till att krafterna tas upp genom diaphragm action (skivverkan) and avoid introducing stress concentrations on the fatigue loaded parts.
Plate action (Plattverkan) – the forces being introduced into the head structure with a component perpendicular to the plate high bending stresses and deformations!
The ability to take up loads perpendicular to the plate
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75 IWSD M3.3
Load paths
Exploit disc / diaphragm effect !
disc / diaphragm effect (Skivverkan) – loads entering the plate plane. Stresses and deformations more favorable at reduced plate thickness than in plate action
The ability to take up loads in the plate plane
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76 IWSD M3.3
Load paths
Fastening of a cantilever beam to the main beam
• The various cross-sections appears as discs.
• The bending moment caused by the force P is taken up in the form of a force couple in the flanges, and the lateral force taken up by shear forces in the webs
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77 IWSD M3.3
Load paths
Plate action d1 < d
Less local bending
Disc action is exploited good!
Suitable is the beam is subjected to fatigue loads
Exemple of load path with reduced local bending of the beam flange
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78 IWSD M3.3
Load paths
Options to reduce stress concentrations
Good when the beam is statically loaded
Good when the beam is subjected to fatigue loads
Bad Better
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79 IWSD M3.3
Load paths – welding of a lifting lug
The load is fed directly into the web, most appropriate section to take up forces
Plate across the beam, the flange is deformed
Weld in line with the web section will take a heavy load
Also the web is affected
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80 IWSD M3.3
Load paths – welding of a lifting lug
Improper placement of the lug
Bending stresses in the web
The forces should instead be directed to the flanges Placing the lug to avoid bending
stresses in web
Risk for Buckling
Use disc action
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81 IWSD M3.3
Load paths – welding of a lifting lug
Improper placement of the lug
Bending stresses in the web
The forces should instead be directed to the flanges
Use disc action
Stiffeners for leading in forces on the web section Prevents flanges deform
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82 IWSD M3.3
Reduce th risk for buckling
Introduce stiffeners - easiest way to distribute the load
Sandwich structure
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83 IWSD M3.3
Reduce th risk for buckling
Example: Stiffners to reduce the risk for buckling. Laserwelded plate to main structure within civil aircraft industry.
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84 IWSD M3.3
Design to avoid corrosion
Bad Good Best
Drainage hole
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85 IWSD M3.3
Design to adopt for manufacturing
Save material, details and costs
Bad Good
Reduce tolerance dependence Bad Good
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86 IWSD M3.3
Design to adopt for manufacturing
Avoid accumulation of welds in one point Bad Good
Reduce shrinkage stress/STRAIN
Bad Good
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87 IWSD M3.3
Design to adopt for manufacturing
Accessibility welding
Bad Good
Unambiguous positioning of the parts for welding
Bad Good
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88 IWSD M3.3
Design to adopt for manufacturing
Redesign to self fixturing so that they directly in assembly may well defined positions
Dåligt Bra
BEFORE AFTER
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89 IWSD M3.3
Design the welds as simple as possible
Welded joints – examples of weld joint design
NOT a rivet joint (nitförband)
Good rivet joints / bolted joints = bad welded joints
Wrong! Correct!
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90 IWSD M3.3
Design the welds as simple as possible
Be sure of the accessibility
Welding pistol
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91 IWSD M3.3
Design the welds as simple as possible
Avoid tensile stresses perpendicular to the sheet thickness
Stress direction
Non-load carrying weld
Failure in weld toe
Stress direction
Load carrying weld
Failure in weld toe and/or root
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92 IWSD M3.3
Design the welds as simple as possible
If the the joint is unymmetric turned in the right direction in relation to the load
weld root side critical and often not accesable avoid tensile stresses
Wrong! Correct!
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93 IWSD M3.3
Design the welded details
Place the welds right with respect to the direction of forces
• Avoid tensile stresses at weld root
• Root side in a symmetric welds is almost always the joints weakest point
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94 IWSD M3.3
Welds – example of proper design
Butt welds are better than fillet welds in fatigue loaded structures
Choosing the right joint geometry
Bad Good
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95 IWSD M3.3
Welds – example of proper design
Transition between different sheet thicknesses leads to increased loading
Avoid high stress concentrations at fatigue loading
Acceptable for static loadind
Good from fatigue point of view
Better from fatigue point of view
Slope min 1:2
Recommended 1:4
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96 IWSD M3.3
Design for welding
Be careful when welding thick material
• Large temperature gradients uneven and rapid cooling
• Large welding residual stresses small possibilities to be reduced by deformations
Avoid welding of thin materials to thick
• Thick material cools rapidly cracks in the weld
• Gradually decreasing thicknesses
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97 IWSD M3.3
Design for welding
Design section transitions so that the notch effect is as small as possible
Low notch effects
High notch effect
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98 IWSD M3.3
Design for welding
In fatigue loaded structures - avoid the stress concentrations in highly stressed areas (welds, holes, etc.)
Examples of placement of stress concentrations in low stressed areas
Better
Bad
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99 IWSD M3.3
Reduced weld filler material Accessability
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100 IWSD M3.3
Adjust for mechanised welding
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101 IWSD M3.3
Tolerance requirements for weld tourch angle
Butt weld
Bevel butt weld
Fillet weld
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102 IWSD M3.3
Welded Rectangular Hollow Sections (RHS)
Welding of fillet welds facilitates mechanization
Backing plate for butt-welding
Few continuous, intermittent welds reduces the risk of deformations
Welds symmetrically to the neutral axis
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103 IWSD M3.3
Welded RHS
Butt Welded corners with and without stiffener
Frame corners
The corner is reinforced with a RHS
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104 IWSD M3.3
Example: Weld design of a mobile crane
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105 IWSD M3.3
Example: Weld design of a mobile crane
Previous design
Only one plate Only one weld No weld preparation, groove
Weld is not in the neutral axis of the beam Give rise to high bending stresses in the weld
Conventional weld
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106 IWSD M3.3
Example: Weld design of a mobile crane
Current design
Laser-hybrid welds
Laser welding where no bevel groove is necessary Hybrid welding; where corner effects from bending results in variable gap along the seam welds
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107 IWSD M3.3
Example: Weld design of a mobile crane
Production-related reasons for new design
Difficult to position the plate ends for correct welding
Difficult to guarantee full penetration welds without penetrating through / backing plates
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108 IWSD M3.3
Example: Weld design of a mobile crane
Mechanical-related reasons for new design
Large global bending stresses in the weld
Great local deformations / stresses from telescopic beams plates
Tangential stresses at the beam ends
Longitudinal stresses
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109 IWSD M3.3
Example: Weld design of a mobile crane
Laser hybrid welding
Welding at Luleå Technical University, Sweden
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110 IWSD M3.3
Stiffeners in the corners
In static load and low fatigue loads
At large fatigue loads
The best solution is achieved if the cut out is designed as a third arc or a prolonged arc. Both of these configurations provide two elastic tongues that provides a favorable stress flow at welding around the cut-out corner. Grinding as in figure e) gives soft transition
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111 IWSD M3.3
Bad design practice
Lack of access Lack of visibility
Lack of clearance
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112 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Study on weld quality and good design
Bogie beam
Bogie beam
Goal decrease weight by 20 % by • Using High Strength Steel • Redesign
• Improvement techniques
• Validation by testing
• Reduce production cost
• Justify less environmental impact
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113 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Old design compared with new design
Old design • t = 15 / 8 mm • 183 kg • Steel grade = 350 MPa
New design • t = 12 / 6 mm • 143 kg (- 22 %) • Steel grade; use High Strength Steel
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114 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Max static load Desicision of material grades
• Bearing 350 MPa grade • Flanges 460 MPa grade • Webs 600 MPa grade
Buckling strength is approx. 4 times max load
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115 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Fatigue testing and life prediction
Bogie beam (fatigue life in hours)
Target > 1000
Testing 930
Prediction (Global) 120
Prediction (Local) 700
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116 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Study on weld quality and good / bad design
Test of bogie No. 1 – Failure after 120 hours
• Expected fatigue life > 1000 hours • Failure after 120 hours
• Due to lack of fusion (weld penetration requirements I = 2 mm)
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117 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Study on weld quality and good / bad design
Test of bogie No. 2 – Failure after 250 hours
• To verify test No. 1 • Result: Failure after 250 hours in tack weld / fixture • Cause: lack of fusion due to production mistake in plug weld
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118 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Study on weld quality and good / bad design
Test of bogie No. 3 – Failure after 920 hours
• Full penetration fillet weld • Now failure from toe side
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119 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Study on weld quality and good / bad design
Test of bogie No. 4 – first crack at 790 hours, test stopped at 940 hours
• Full penetration fillet weld • TIG dressing at weld toe • No tack weld • Improved flange geometry
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120 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Cost estimation for production
Lower weight and production cost ”Win-Win” situation for customer and producer!
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121 IWSD M3.3
Case study: Lightweight design of bogie beam structure in a Volvo CE Hauler
Environmental impact and cost saving during the life time of the vehicle
• 90 % of environmental savings are during the use phase • Weight reduction lead to less fuel consumption, increased payload... • Life time cost saving of 840 Euro /vehicle
Total CO2 savings due to weight reduction of the bogie beam
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122 IWSD M3.3
Design philosophy - fatigue
Infinite-Life
Loads are well below the threshold
Safe-Life
Load spectra known, part replaced at intervals
Fail-Safe
Safety factor, multiple load paths and redundancy
Damage Tolerance
Regular inspections, fracture mechanics
Heavy structures
Optimized structures
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123 IWSD M3.3
Design philosophy - general
• Allowable stress design
- allowable stress method = actual loads wiyh an arbitrary factor on strength
• Limit state design
- ultimate limit state method = (differently) factored loads and actual strength
- serviceability limit state method = actual loads and actual behavior
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124 IWSD M3.3
Design philosophy - general
• Allowable stress design - allowable stress method = actual loads with an arbitrary factor on strength, used for over 100 years
• Limit state design - ultimate limit state method = (differently) factored loads and actual strength
- serviceability limit state method = actual loads and actual behavior
- A limit state means “A set of conditions at which a structure ceases to fulfill its intended function
- First introduced in 1986