Mechanical Engineering Laboratory of Steel Structures

Mechanical Engineering

Laboratory of Steel Structures

6/2010

Research Group of

Steel Structures

Laboratory of

Steel Structures

Main entrance

LABORATORY OF

STEEL STRUCTURES

STEEL STRUCTURES

• Research group of Steel Structures is working on design and fabrication of metal structures for demanding energy-efficient applications

• We are creating novel ideas and rules for design and fabrication procedures especially for design with high- and ultra-high strength steels (UHSS)

• The investigation includes theoretical analyses, numerical simulation and experimental testing. Laboratory of Steel Structures has good facilities for testing, also at low ambient temperatures

• Current main research topics include• Fatigue and static strength of welded joints

• Performance of welded structures made of UHSS

• Simulation and measurement of residual stress and

their effect on structural behavior of structures

• Digitized life cycle control including design, fabrication

and service of metal constructions

LABORATORY OF

STEEL STRUCTURES

RESEARCH TOPICS – STEEL STRUCTURES

Increase of material strength in structural steelsa) Design of steel structures

b) Analyzing the behavior of steel structures imposed to different load conditions

• Especially capacity of welded joints

• Static and fatigue strength made of high or ultra-high strength steels

→ ENERGY EFFICIENCY

• Digitization of the production (design and fabrication)

• supporting topics: FEA, simulations, experimental static/fatigue testing, arctic conditions

c) Collaboration with Finnish industrial companies

d) International cooperative universities

LABORATORY OF

STEEL STRUCTURES

DIGITIZED DESIGN

- Material selection

- Structural design and analysis

- Design of fabrication and manufacturing

parameters

TOOLS FOR ANALYSIS

- 4R method, XX-FAT

- 3D modeling

- FEA

- Structural simulations

- Welding simulations

- CPS, CFPS, WPS (parameters, tack welds,

welding positions, sequence of welding)

- Preparation of components

- Digitized jig

- Robotic welding cell

- Robotized welding

- Adaptivity

- Post-weld treatments

- Digitized qualitative

documents

- Assembly

- Surface treatments

DIGITIZED

MATERIAL,

DESIGN AND

FABRICATION

DATA

- Service of product

- Loading

- Maintenance

- Recycling

- Residual fatigue strength

- Transient degree of loading

- Compiling statistical load

histories

- Predictable service life

- Independency and reliability

Real time load

history for user

Material

DIGITIZED STRUCTURAL DESIGN

AND DESIGN OF FABRICATION

PRODUCT

TIME-DEPENDENT LOAD HISTORY

FOR DESIGN PURPOSES

FEEDBACK TO MATERIAL DEVELOPMENT

Design Fabrication Inspection Product

DIGITIZED FABRICATION

REAL TIME FATIGUE

MONITORING

END USER

MA

TE

RIA

L D

ES

IGN

AN

D P

RO

DU

CT

ION

ACTUAL

FABRICATION

QUALITY

DIGITIZED DESIGN AND FABRICATION

LABORATORY OF

STEEL STRUCTURES

DIGITIZED PRODUCTION

DESIGN

Material

selection

MA

TE

RIA

L P

RO

DU

CT

ION

Structural

design

Design of

fabrication

SERVICEFABRICATION

- Cutting

- Cold Forming

- Machining

- Tack welding

- Welding

- Post-treatments

- Inspection

- Assembly

- Transportation

- Installation

Real-time load history for design purposes

Feedback to material development

Fabrication quality for design purposes

F

t

CuPS: geometry, process, Q, v

TPS: geometry, a, f, v (n, d)

CFPS: x, θ, r, orientation

DPS: tool, f, v (n, d) TWPS:WPS:

location

sequence

U, I, v

location

position

sequence

n, Un, In, vn, β, ϕ

Q

v

v

af

r

x

θ

f

vϕ

βv

U, I

IPS:

Quality

measurements:

a) critical

parts/welds

b) all welds

ReF

aMo

LABORATORY OF

STEEL STRUCTURES

4R METHOD FOR FATIGUE DESIGN OF WELDED JOINTS AND COMPONENTS

-400

-200

0

200

400

600

800

-0,001 0,004 0,009 0,014 0,019

σ

ε

Ramberg-Osgood:

σmin

σmax

σk,min

σk,max

ASW, σres > 0

HFMI, σres < 0

σres

σres

σk,max

σk,min

σk,max

σk,min

No relaxation

Relaxation

Relaxation of residual stresses:

1/n

E H

= +

Neuber:2

,max( )k res

E

+=

1/

22

n

E H

= +

cyclic R-O:

Neuber:2

k

E

=

Novel multi-parametric fatigue assessment approach that considers:

• Material ultimate strength (Rm)

• Residual stresses (σres)

• External stress ratio (R)

• Weld toe radius (rtrue)

Acting stress ratio (Rlocal) at notch root is obtained using well-known material models (Ramberg-Osgood and Neuber’s notch theory) considering the four essential parameters

LABORATORY OF

STEEL STRUCTURES

S-N CURVES OF 4R METHOD

100

1000

1,00E+04 1,00E+05 1,00E+06 1,00E+07

Material S1100 │ Loading R = -1 │ σres = -460 MPa

FAT225

4R

FAT500

Δσk [MPa]

Nf [cycles]

Master Curve

100

1000

1,00E+04 1,00E+05 1,00E+06 1,00E+07

Material S700 │ Loading R = -1 │ σres = -330 MPa

FAT225

4R

FAT400

Δσk [MPa]

Nf [cycles]

Master Curve

100

1000

1,00E+04 1,00E+05 1,00E+06 1,00E+07

Material S700 │ Loading R = 0│ σres = -330 MPa

FAT225

4R

FAT400

Δσk [MPa]

Nf [cycles]

Master Curve

LABORATORY OF

STEEL STRUCTURES

REFAMO – REAL-TIME FATIGUE MONITORING

ReFaMo measures, analyses the measured loading, and calculates and visualizes the remaining 4R fatigue life and current degree of loading

ReFaMo solves the problems related to processing of large amount of measured data, structural health monitoring and inaccuracy of design loads

LABORATORY OF

STEEL STRUCTURES

CATEGORIZATION OF STRESS COMPONENTSUNDER AXIAL LOADING

Total stress distribution

Membrane stress distribution Bending stress distribution Non-linear stress peak

σs = σm + σb

σtot = σm + σb + σnlp σmσb σnlp

σtot

X

Y [mm]

X [mm]

LABORATORY OF

STEEL STRUCTURES

CATEGORIZATION OF STRESS COMPONENTSUNDER BENDING LOADING

Total stress distribution

Membrane stress distribution Bending stress distribution Non-linear stress peak

σs = σm + σb

σtot = σm + σb + σnlp σm

σbσnlp

σtot

Y [mm]

X [mm]

LABORATORY OF

STEEL STRUCTURES

STAFFTIMO BJÖRK

Professor, Head of the laboratory

MATTI KOSKIMÄKI

Laboratory Engineer

OLLI-PEKKA PYNNÖNEN

Laboratory Technician

JARI KOSKINEN


ANTTI AHOLA

Junior Researcher

HELI METTÄNEN

Junior Researcher

SHAHRIAR AFKHAMI

Junior Researcher

MEHRAN GHAFOURI

Junior Researcher

MOHAMMAD DABIRI

Post-Doctoral Researcher

RIKU NEUVONEN

Junior Researcher

MIKA KÄRMENIEMI


JAN MUURONEN


ALEXEI YANCHUKOVICH

Junior Researcher

MOHSEN AMRAEI

Visiting Researcher, Sydney UNSW

No. of Master Thesis Workers at LUT: 5 (04/2019)

LABORATORY OF

STEEL STRUCTURES

”Theory and experiments should be thought

of as completing each other,

and the engineer who takes this attitude will, in

general, be a more effective problem solver

than one who neglects one or the other of

these two approaches.”

Doebelin E.O.

LABORATORY OF

STEEL STRUCTURES

LUT UniversityMechanical Engineering

Laboratory of Steel Structures

Research Facilities

LABORATORY OF

STEEL STRUCTURES

▪ Laboratory have seven (7) servo hydraulic load frames for dynamic and static loading test set-ups.

▪ Biggest test rig in Finland for dynamic testing up to 5 MN compression and tension loading.

• Equipped with movable environment chamber down to -60°C to determinate material and connections

behaviour at sub zero temperatures.

• Full-scale tests of components made of high- and ultra-high-strength steels (S700-S1100).

5MN load

frame Environment chamber + Cooling unit

MATERIAL TESTING MACHINES (LOAD FRAMES)

LABORATORY OF

STEEL STRUCTURES

▪ 5 MN for static and dynamic loading

▪ 1200 kN and 750 kN for dynamic and static loading

▪ 400 kN for dynamic and static loading

▪ Hz1 and Hz2 frames for 150 kN dynamic and static loading

▪ 150 kN for dynamic and static loading

▪ 1 MN compression up to 7 m length columns and beams

▪ Drop weight testing machine for impact tests


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LABORATORY OF

STEEL STRUCTURES

▪ Load frame for RHS K-joints

• Designed in Laboratory of Steel Structures based on the knowledge of 30 years of testing

experience

• Static chord force up to 2 MN and diagonal force up to 1.2 MN

Cooling capability for subzero tests down to -60°C


LABORATORY OF

STEEL STRUCTURES 18

FULL-SCALE TEST SET-UPS

DYNAMIC AND STATIC LOADING

videot/explosion.mpg

LABORATORY OF

STEEL STRUCTURES

▪ Main frame of Underground Loading and hauling machine

FULL SCALE TEST SETUPS


LABORATORY OF

STEEL STRUCTURES

FULL SCALE TEST SETUPS


20

▪ Lab floor space: 11 m x 29 m = 319 m2

• height 4.5 m (hoist)

▪ T-slot floor with 400 mm spacing (M20)

• T-slot areas:

• 2 x (9,6 m x 4 m) , total length of 21 m

• 4 m x 3,2 m

• T-slot loading table 4 m x 3.5 m

(M24 - 250)

LABORATORY OF

STEEL STRUCTURES

MEASUREMENTS of SPECIMENSHP-L-20.8 Laser Scanner for ROMER Absolute Arm

Detailed 3D-2D-

geometry for fatigue

analysis

LABORATORY OF

STEEL STRUCTURES 22

MEASUREMENTS OF SPECIMENS

sin2d=

▪ X-ray diffraction device for residual stress measurements

LABORATORY OF

STEEL STRUCTURES

MEASUREMENTS OF SPECIMENS

Optical 3D Deformation Analysis, Digital image correlation (DIC)

device with 12MPa cameras

ARAMIS

LABORATORY OF

STEEL STRUCTURES25

High Frequency Mechanical Impact Treatment (HFMI)

▪ Improvement of fatigue of welded structures as much as 5 times better fatigue life.

• As welded condition FAT95% =97 vs. HFMI treated condition FAT 95% =175

LABORATORY OF

STEEL STRUCTURES

INSTRUMENTATION

▪ Strain Gauges, Transducers, Aplifiers, Data Acquisition.

LABORATORY OF

STEEL STRUCTURES

MICROSECTIONS and FIGURES

LABORATORY OF

STEEL STRUCTURES

TOOLS for CALCULATION AND ANALYSIS

▪ FEA: ABAQUS, FEMAP/Nastran, Franc2D, LS/DYNA, tailor-made programs

▪ Others: Mathcad, Mathlab, Solidworks, AutoCad, etc..

LABORATORY OF

STEEL STRUCTURES

LUT SCOPUS: Welded UHSS (Weld+Ultra+High+Strength+Steel)

LABORATORY OF

STEEL STRUCTURES

HRO SUUNNITTELUFOORUMI

T=-40 °C

ABB Oyj

Allu Finland Oy

Andritz Oy / Hollola / Savonlinna

Auramo Oy

BMH Technology Oy

Bronto Skylift Oy Ab

Cargotec Finland Oy

Deltamarin Oy

EDR & Medeso Oy

Eisto Oy

Elomatic Oy

Etteplan Design Center Oy

HT Laser Oy

John Deere Forestry Oy

Junttan Oy

Konecranes Global Oy

Mantsinen Group Ltd Oy

Metso Minerals Oy

Meyer Turku Oy

NDT Inspection & Consulting Oy

Neteram Oy

One Moment Engineering Oy

Outotec Oyj

Ponsse Oyj

Raahen Insinöörisuunnittelu Oy

Raute Oyj

Sandvik Mining and Construction Oy

SSAB Europe Oy

STALATUBE Oy

Stressfield Oy

The Switch

TMT Malinen Oy

Unisigma Oy

Valmet Technologies Oy

Valtra Oy Ab

Waratah OM Oy

Viafin Terästorni Oy

Wärtsilä Finland Oy

• Teräsrakenteiden laboratorion koordinoima foorumi vaativien rakenteiden suunnittelijoille,

tuotekehittäjille ja tutkijoille sekä valmistuksesta, tarkastuksesta ja kunnossapidosta vastaaville

• SHY:n Suunnittelufoorumi

• Yhteensä 38 + jäsenyritystä

• Tavoitteet:

✓Tuottaa uutta tutkimustietoa (tutkimusprojektit + HRO diplomityöt)

✓Toteuttaa Suomen hitsaavan teollisuuden kannalta tärkeitä tutkimusprojekteja (BF, SA, EU..)

✓Välittää uusin tarpeellinen tutkimustieto maailmalta kotimaiselle teollisuudelle (IIW)

✓ Luoda ja ylläpitää alan yritysten välisten yhteistyötä ja kontaktointia

✓Tuottaa palvelututkimusta ja koulutusta yrityksille (HRO alennus jäsenyrityksille)

• HRO Suunnittelufoorumin teemapäivät

✓Alan viimeisimpien tutkimustulosten esittely (LUT + tutkimuslaitokset)

✓Jäsenyritysten ja kutsuvieraiden omat esitykset

✓Kansainvälinen vieraileva luennoitsija

✓Kaksipäiväiset vuosittain

LABORATORY OF

STEEL STRUCTURES

NEED MORE INFORMATION?

WE ARE HERE FOR YOU,

DO NOT HESITATE TO ASK

➢Professor Timo Björk: [email protected]

➢Laboratory Engineer Matti Koskimäki: [email protected]

Mechanical Engineering Laboratory of Steel Structures

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Transcript of Mechanical Engineering Laboratory of Steel Structures