mechanical engineering laboratory of steel structures
TRANSCRIPT
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
Laboratory Technician
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
Laboratory Technician
JAN MUURONEN
Laboratory Technician
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
MATERIAL TESTING MACHINES (LOAD FRAMES)
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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
MATERIAL TESTING MACHINES (LOAD FRAMES)
LABORATORY OF
STEEL STRUCTURES 18
FULL-SCALE TEST SET-UPS
DYNAMIC AND STATIC LOADING
LABORATORY OF
STEEL STRUCTURES
▪ Main frame of Underground Loading and hauling machine
FULL SCALE TEST SETUPS
DYNAMIC AND STATIC LOADING
LABORATORY OF
STEEL STRUCTURES
FULL SCALE TEST SETUPS
DYNAMIC AND STATIC LOADING
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 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
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T=-40 °C
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tuotekehittäjille ja tutkijoille sekä valmistuksesta, tarkastuksesta ja kunnossapidosta vastaaville
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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]