Fatigue design in penstocks – comparison of the nominal stress and structural stress method for common details

ce/papers ◽  
2021 ◽  
Vol 4 (2-4) ◽  
pp. 1126-1134
Author(s):  
Alexander Ecker ◽  
Harald Unterweger
1999 ◽  
Author(s):  
Haruo Sakamoto

Abstract This paper describes the codes and practice for designing welded structures such as railroad truck frames. For designing the first configuration, rather simple criteria are desired, although most codes such as AWS. AISC, etc. are complex. They consist of a variety of welded joint categories, which make a designer feel uncomfortable when deciding the first configuration. Therefore, such codes are considered to be mainly used for the evaluation of designed and constructed structures, and not to be used for deciding the first configuration. The JIS (Japanese Industrial Standard) for a railroad truck frame is explained as an example of a simple code, and is compared with some fatigue data. This standard is thought to be useful for a designer. However, the result of this investigation suggests a modification of the JIS for obtaining more reasonable criteria. Desirable criteria should be simple for a designer and sufficiently safe for structures. Additional investigations on fatigue data of welded joints, a statistical study for desirable non-fracture probability, and methods of structural stress analysis are to be conducted in the future. A practical fatigue testing method is also needed for investigating the strength in a high cycle region such as 108.


Author(s):  
M-H Kim ◽  
S-W Kang

At present, the fatigue design of welded structures is primarily based on a nominal stress or hot spot stress (HSS) approach with a series of classified weld S-N curves. Although well accepted by major industries, the nominal stress-based fatigue design approach is relatively cumbersome in terms of securing a series of S-N curves corresponding to each class of joint types and loading modes. Moreover, it is very difficult, if not impossible, to determine the nominal stress at each structural component, particularly in complex ship structures. The HSS-based fatigue design is based on the stress at the weld toes obtained by linear or quadratic extrapolation of stresses over two or three points in front of the weld toe. Finite-element analysis is mostly applied. However, this method has a difficulty of finding a proper stress through the global model, the medium size model and the detail model of ship structure. Besides, the calculated HSS values may vary depending on the extrapolation technique used. Recently, a mesh-size insensitive structural stress (SS) definition that gives a stress state at the weld toe with a relatively large mesh size has been proposed. The SS definition is based on the elementary structural mechanics theory and provides an effective measure of a stress state in front of the weld toe. As an experimental validation of the Battelle SS method in obtaining the fatigue strength of weldments, a series of experiments are carried out for various sizes of weldments. Based on the results from this study, it is expected to achieve the development of a more precise fatigue strength evaluation technique and saving on the time required in the fatigue design of ship and offshore structures.


2013 ◽  
Vol 838-841 ◽  
pp. 314-318
Author(s):  
Hang Gang Guo ◽  
Jin Zhang ◽  
Yang Zhang ◽  
Wei Zhang

Though fatigue failure is often happened in steel gate, fatigue design has not yet been included in design or evaluation standards in China. In this paper, analytical theory based structural stress method and structural stress based fatigue analysis method are combined and employed for fatigue life evaluation of plane steel gate. The variation of water head is taken into consideration for the conditions of gate running and resting. In order to give a valid evaluation, the weld located among all components is considered as rigid connection when calculating structural stress. Master S-N curve in ASME code is used for life evaluation. Example shows the method can be used for fatigue analysis of plane steel gate, and can be used to identify fatigue failure zone.


Author(s):  
Pingsha Dong ◽  
Jeong K. Hong

A series of well-known tubular joints tested in UKSORP II have been re-evaluated using the mesh-insensitive structural stress method as a part of the on-going Battelle Structural Stress JIP efforts. In this report, the structural stress based analysis procedure is first presented for applications in tubular joints varying from simple T joints, double T Joints, YT joints with overlap, and K joints with various internal stiffening configurations. The structural stress based SCFs are then compared with those obtained using traditional surface extrapolation based hot spot stress methods. Their abilities in effectively correlating the fatigue data collected from these tubular joints are demonstrated. These tests are also compared with the T curve typically used for fatigue design of tubular joints as well as the structural stress based master S-N curve adopted by ASME Section VIII Div 2. Finally, some of the implications on fracture mechanics based remaining life assessment for tubular joints are discussed in light of the results obtained in this investigation.


2005 ◽  
Vol 127 (1) ◽  
pp. 68-74 ◽  
Author(s):  
P. Dong

Recent rapid advances in developing mesh-insensitive structural stress methods are summarized in this paper. The new structural stress methods have been demonstrated to be effective in reliably calculating structural stresses that can be correlated with fatigue behavior from simple weld details to complex structures. As a result, a master S–N curve approach has been developed and validated by a large amount of weld S–N data in the literature. The applications of the present structural stress methods in a number of joint types in offshore/marine structures will be illustrated in this paper. The implications on future applications in drastically simplifying fatigue design and evaluation for offshore/marine structures will also be discussed, particularly for using very coarse finite element mesh designs in ship structures.


Author(s):  
P. Dong

Recent rapid advances in developing mesh-insensitive structural stress methods are summarized in this paper. The new structural stress methods have been demonstrated to be effective in reliably calculating structural stresses that can be correlated with fatigue behavior from simple weld details to complex structures. As a result, a master S-N curve approach has been developed and validated by a large amount weld S-N data in the literature. The applications of the present structural stress methods in a number of joint types in offshore/marine structures will be illustrated in this paper. The implications on future applications in drastically simplifying fatigue design and evaluation for offshore/marine structures will also be discussed, particularly for using very coarse finite element mesh designs in ship structures.


2012 ◽  
Vol 468-471 ◽  
pp. 663-667
Author(s):  
Da Shan Dong ◽  
Chun Yan Lu ◽  
Yuan Yuan Teng

The paper is based on nominal stress method and MSC.FATIGUE software, adopts virtual fatigue design method, take cart balance beam of quayside container crane as an example, build its finite element model, conduct strength analysis on the balance beam and fatigue analysis under specified load course by MSC.Fatigue software, then obtain life distributions which can provide the basis of nichetargeting improvement and fatigue research in design stage. Through above analysis, it has been proved the feasibility of the method that the paper adopted, and it can greatly reduce the expense that the fatigue life testing brings about.


Author(s):  
Masahiro Takanashi

This paper discusses fatigue design margins based on large-sized specimens that are considered to be more closely related to actual components. A fatigue design curve is generally determined by applying an adequate margin to a best-fit curve obtained from laboratory tests using small-sized specimens. However, the reason and the background for the margin setting are unclear and controversial. In ASME Boiler and Pressure Vessel Codes Section III, for example, a factor of 2 on stress and a factor of 20 on life are applied to the best-fit curves. The conservatism of these factors has been the topic of discussion recently. In addition to a basic method like ASME Section III, new design concepts for welded structures, equivalent structural stress approach, has been proposed recently and adopted to design codes in Europe (EN13445) and the U.S. (ASME Section VIII Division 2). Thus, the design margins by these three methods were compared. The comparison made it clear that the ASME Sec. III method gives the most conservative margin, and the lowest value is approximately 2.


Author(s):  
Jeong K. Hong

Reliable structural integrity evaluation is a critical part of the design process. Reliable structural integrity evaluation is especially important for large and complex structures such as buildings and offshore/marine installations that have significant implications for human and environmental safety. The design and careful evaluation of welded structures are essential in structural design since the stress concentrations at the welds have significant impact on the overall fatigue lives of the structures. A mesh-insensitive structural stress method has been developed and proven to be highly effective in correlating fatigue behaviors of welded joints by Battelle researchers. The Battelle structural stress method and related weld fatigue master S-N curve approach has been adopted by ASME and API in 2007 [1–2]. The design fatigue master S-N curve has been constructed by incorporating the results of more than 800 fatigue tests, which are clearly categorized as weld toe failure. In addition, a design master S-N curve for weld root failure has been constructed recently [3]. For offshore/marine structures, it is essential to consider weld fatigue damage in corrosive environments as well as that in air, and to understand the effects of techniques commonly applied to improve weld fatigue strength of the structures, e.g., hammer peening, toe grinding, and TIG dressing. In order to meet the industry’s increasing demand for reliably, fatigue resistant structures, design master S-N curves incorporating the effects of corrosive environments and weld improvement techniques have been constructed. These new curves are based on existing weld fatigue data from the literature and class bodies’ fatigue design documents.


Author(s):  
Zhigang Wei ◽  
Pingsha Dong ◽  
Jeong K. Hong ◽  
Thomas P. Forte

In this paper, a path-dependent maximum range (PDMR) multi-axial cycle counting method is presented for performing fatigue life assessment of engineering components under general variable-amplitude multi-axial loading conditions. The PDMR method has two distinct features: (a) multi-axial cycle counting, in which the cycle counting is conducted in an equivalent stress or strain space, and (b) explicit loading path dependency. For uniaxial loading data, the PDMR and the ASTM standard Rainflow methods both generate the same counting results. The path-length, a function of both normal and shear stress components on a critical crack plane, is proposed as a fatigue damage parameter for ductile materials. PDMR can be applied to welded structures, in which the crack plane is usually known in advance, as well as to non-welded structures, in which the critical plane approach can be implemented into PDMR to determine both the fatigue crack orientation and the associated fatigue damage. The effectiveness and robustness of the PDMR method have been validated by its ability to correlate nominal stress and Battelle structural stress fatigue data including pure-bending, pure-torsion, in-phase, and out-of-phase loading conditions for welded tube-to-flange steel structures. The relationship between the data correlations based on nominal stress and Battelle structural stress for these loading conditions is illustrated. Finally, one-parameter and two-parameter equivalency approaches for PDMR operation are also introduced and discussed.


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