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Corrugated web beams are an alternative to steel girders with flat webs. They consist of a welded Isection with a thin-walled trapezoidally corrugated web and flanges made of wide flat steel. In comparison with hot-rolled or welded I-beams with flat webs, corrugated web beams offer significant material savings and are produced fully automated. Assuming the same load-bearing capacity, corrugated web beams are lighter than those with a flat web, since the corrugated web beams can often be loaded up to their plastic resistance without reinforcement of the web. Research on the loadbearing behaviour of corrugated web beams without web openings is well-established. However, the resistance of corrugated web beams with reinforced web openings, which are necessary for installations in buildings, has not been well investigated experimentally yet. This paper examines the shear force resistance of trapezoidally corrugated web beams with reinforced square web openings. Two beam-like specimens with the same geometry but differently reinforced web openings were tested. The experimental results are compared with a Finite Element Analysis using Abaqus® and with an analytical model that allows a simplified calculation. The comparison identifies how the wall thickness of the web opening reinforcement affects the shear force resistance of perforated corrugated web beams.
Wenn an Stahlbrückenkonstruktionen Ermüdungsrisse festgestellt werden, treten
diese in der Regel an kerbscharfen Konstruktionsdetails auf. Die Instandsetzung der
betroffenen Brückenkonstruktion erfordert in den meisten Fällen umfangreiche Sa
nierungsmaßnahmen, die oft mit einer Brückensperrung und erheblichen Beein
trächtigungen der Verkehrsinfrastruktur einhergehen. Im Rahmen eines ZIM
Forschungsvorhabens [3] wird derzeit ein innovatives Reparaturverbundsystem aus
kohlenfaserverstärktem Kunststoff (CFK) entwickelt, das mithilfe von Klebetechnik
appliziert wird und das angerissene Bauteil lokal verstärkt. Das primäre Ziel dieser
verstärkenden Maßnahme besteht darin, mittels individuell gefertigter CFK-Schalen,
welche durch die Verwendung eines zweikomponentigen Klebstoffs am Hänger be
festigt werden, den Riss zu überbrücken. Auf diese Weise soll der Rissfortschritt
signifikant reduziert oder gestoppt werden. Dieser Beitrag gibt einen Überblick über
die ersten Ergebnisse aus diesem Forschungsvorhaben.
Im Rahmen des Beitrags wird das Tragverhalten von Trapezstegträgern mit quadra
tischen Öffnungen und Öffnungskränzen (umlaufende Versteifung) als Verstär
kungsmaßnahme untersucht. Die Ergebnisse aus zwei Traglastversuchen und einer
umfangreichen numerischen Parameterstudie (FE-Berechnungen) zum Tragverhal
ten von Trapezstegträgern mit versteiften quadratischen Stegöffnungen werden vor
gestellt. In der Parameterstudie werden die Einflüsse der Kranzdicke und der geo
metrischen Imperfektionen auf die Querkrafttragfähigkeit der Trapezstegträger un
tersucht. Schlussendlich wird ein praxisnaher Bemessungsvorschlag zur Ermittlung
der Querkrafttragfähigkeit von Trapezstegträgern mit versteiften Stegöffnungen vor
gestellt.
Geometric Properties of Steel Components with Stability and Fatigue Risks Using 3D-Laser-Scanning
(2024)
Nowadays, 3D laser scanning technology is extensively employed in laboratory investigations of steel structural components, providing accurate geometric dimensions to reduce uncertainties caused by indeterminate geometry in experimental results. It is often used in conjunction with the Finite Element (FE) Method and analytical solutions, which are more accurate deterministic operators in the research on steel structures. However, establishing a common methodological framework for transferring or mapping 3D-scanned information into finite element models for complex steel structures with stability and fatigue risks remains an ongoing task. In light of this, this study has developed a 3D scanning platform capable of obtaining accurate geometric dimensions for various types of steel components. Different coordinate systems and point cloud mapping algorithms have been established for different types of components to construct actual finite element models with initial imperfections. The feasibility of the self-developed 3D scanning platform and finite element modelling has been validated through three experimental cases: weld details, steel girders, and cylindrical shells. The research findings demonstrate that the captured point cloud can be automatically processed and corrected using the developed algorithm. The scanned data can then be input into the numerical model using various mapping algorithms tailored to the specific geometric properties of the specimens. The differences between the experimental test results and the simulated results obtained from the 3D-scanned finite element models remain within a small range. The self-developed 3D scanning platform and finite element modelling technique effectively capture the actual dimensions of different steel components, enabling the prediction of their stability and fatigue risks through numerical simulations.
Die nicht ausdrücklich definierte Schnittstelle zwischen Kran (Maschinenbau) und Kranbahnträger (Bauwesen) führte in der Vergangenheit immer wieder zu Missverständnissen in der Praxis in Hinblick auf die Bemessung geklemmter Kranschienen mit Fußflansch (Form A). Von den Kranherstellern wird lediglich die Kontaktpressung zwischen dem Laufrad des Krans und der Schienenoberfläche nach EN 13001-3-3 nachgewiesen. Die Bemessung der Kranschiene selbst wird nicht durch die Vorschriften des Kranbaus geregelt. Auf der anderen Seite ist eine Bemessung geklemmter Kranschienen, die neben zweiachsiger Biegung auch Torsion infolge exzentrischer Lasteinleitung erfahren, bislang aufgrund fehlender Bemessungsregeln nicht ohne Weiteres nach EN 1993-6 möglich. Dieser Beitrag stellt den derzeitigen Stand der für den Normentwurf prEN 1993-6 entwickelten Bemessungsregeln vor und präsentiert Vergleiche mit realitätsnahen numerischen Untersuchungen. Darüber hinaus wird ein verbessertes Berechnungsmodell für die Längsspannungen aus zentrischer Radlast vorgestellt, das im Vergleich zum Normentwurf das tatsächliche Tragverhalten deutlich besser abbildet. Außerdem wird ein Bemessungsvorschlag für einen Ermüdungsnachweis formuliert.
Anwenderfreundlichere Regelungen zu den Einwirkungen aus Kranbetrieb im Norm-Entwurf prEN 1991-3
(2023)
Die Ergebnisse aus drei Traglastversuchen und einer umfangreichen numerischen Parameterstudie (FE-Berechnungen) zum Tragverhalten von Wellstegträgern mit quadratischen Stegöffnungen werden vorgestellt. Es werden versteifte Stegöffnungen mit einem umlaufenden Versteifungskranz betrachtet. In der Parameterstudie werden die Einflüsse der Stegöffnungsgeometrie, der Trägergeometrie und der Position der Stegöffnung auf die Querkrafttragfähigkeit der Wellstegträger untersucht.
Innovative Klebstoffe ermöglichen das zuverlässige und dauerhafte Fügen von natürlichen Baustoffen wie Holz und Holzwerkstoffen mit leistungsfähigen kohlefaserverstärkten Kunststoffen (CFK) zu neuartigen Verbundwerkstoffen. Dadurch eröffnen sich neue Einsatzmöglichkeiten für eine nachhaltige Holzbauweise, die in den letzten Jahren mit Blick auf die Nachhaltigkeitsziele Deutschlands vor allem im Wohnungs- und Geschossbau verstärkt vorangetrieben wird.
Developed numerical Analysis of Residual Stress caused by Welding and Cutting in Steel Structures
(2023)
The welding and flame‐cutting process in the steel construction are commonly used, especially for the bridge structure. Some experiments about welding and cutting have been done separately by some researchers. The results from the experiments were also compared with the results from the numerical simulation under 3D or 2D models. The agreements between those results are as good as they predicted. Therefore, the numerical simulation is a better way to analyze the quality of the steel construction after welding and cutting without time‐consuming and a large amount of cost. But there are only a few research about the numerical simulation and the some of them are aimed to verify the experiments. In this study, the calculation about the residual stresses after welding and thermo‐cutting are considered from 3D‐model into 2D‐Model. The heat source model is simply regarded as curves of time and welding energy with the algorithm methods. And no matter the change of the parameters of the model and the heat source, the heat transfer and the residual stresses can be calculated with the 2D models as fast as possible. By the means of the finite element software Abaqus, the I‐profiles are easy to receive the job results with the input parameters. The influence of the welding and cutting process are visual and direct.
The lateral-torsional buckling resistance of welded steel girders is affected by their residual stresses and geo-metric imperfections. Generally, both influences are mainly controlled by the manufacturing process, in partic-ular the welding of the girder. This paper presents experimental investigations on four laterally unbraced welded steel girders with thin-walled I-sections, whose flange-to-web junctions are welded from one or two sides to evaluate the fabrication influence. The investigations include lateral-torsional buckling tests under combined bending and torsion loading caused by three-point bending due to an eccentric vertical single force. The geometric imperfections of the welded test girders are determined by 3D laser scanning. The test results show that the influence of the geometric imperfections and the residual stresses on the lateral-torsional buck-ling resistance is limited for the tested girders.
Corrugated web beams are welded I‐sections with thin‐walled sinusoidal corrugated webs and flanges made of wide flat steel that have been developed as an alternative to steel girders with flat webs. In comparison with hot‐rolled or welded I‐beams with flat webs, corrugated web beams are connected with considerable material savings and fully automated production. Assuming the same load‐bearing capacity, corrugated web beams are lighter than those with a flat web, since the corrugated web beams can often be loaded up to their plastic resistance without reinforcement of the web. The research on the load‐bearing behavior of corrugated web beams without web openings is relatively mature. However, the resistance of corrugated web beams with reinforced web openings, as they are often used in buildings for installations, has not well experimentally been investigated, yet. This paper deals with the shear resistance of corrugated web beams with reinforced square web openings. Three specimens of different geometry with two square web openings were tested. The experiments are compared with a Finite Element Analysis by Abaqus® and with an analytical model allowing simplified calculation. Both models can relatively accurately calculate the shear resistance. The experimental and numerical results show that the increase of the shear resistance of perforated corrugated web beams depends on the wall‐thickness and the steel grade of the web opening reinforcement.
Fatigue S-N curves of bolts and bolted connections for application in civil engineering structures
(2021)
Bolts and bolted connections are frequently used in civil engineering steel structures. This paper presents a meta study where a few thousand fatigue tests on these elements are evaluated. The evaluation reveals that current specifications in design standards need updating to account for the relevant stress parameter and production methods. This substantially reduces the scatter of the fatigue resistance. The shape and position of the fatigue resistance (S-N) curves also require updating. The results of this study have been implemented in the new revision of European standard EN 1993-1-9. This paper provides the background for the modifications.
The supporting structure ofan overhead traveling crane is subject to cyclic loading. The crane runway beams are parts ofthis structure traveled over by the crane during each cranepassage. Therefore, their fatigue resistance has to be verified according to structural Eurocode 3 in more than 30 countries that are members of European Committee for Standardization (CEN) and potentially more than 50 countriesaround the world. For the verification, the expected fatigue loading during the design service life has to be estimated. A new proposal is presented how to predict the fatigue loading of the crane runway beams based on the type of crane operation.
Application of toughened epoxy-adhesives for strengthening of fatigue-damaged steel structures
(2021)
Reinforcement of Fatigue Damaged Steel Structures Using CFRP Lamellas - Part 3: Numerical Simulation
(2020)
Understanding and predicting sandwich structure behavior in fire has been of particular interest to researchers for a long time. Sandwich panel joints are playing an important role since they not only connect sandwiches to a bearing structure, but also play a key role in stabilization of the whole building. This paper presents an investigation of a sandwich panel behavior. The sandwich panel consist of two steel layers and PIR core between them and is connected to a HEA 160 flange with the help of a screw. Using ABAQUS software, this connection is modelled and deformation fields with temperature distribution area are analyzed. The modelling process includes many stages associated with each other: static, heat transfer and sequential analysis that includes both previous analyses.
Against the background of the earthquake-proof design of steel structures, it makes sense to use structures with sufficient ductility and energy dissipation capacity. The joints are often a weak point in such systems. Methods for reinforcing beam-to-column connections with the aid of adhesively bonded CFRP products are the subject of the work. Advantages of such reinforcement methods are the avoidance of residual stresses (compared to welded steel lamellas), avoidance of cross-sectional weakening (in comparison to bolted solutions) and, above all, the possibility of retrofitting existing steel structures.
In comparison to classic strengthening methods of fatigue-damaged steel structures, adhesively bonded CFRP lamellas show several advantages. Compared to bolted reinforcement measures and the drilling of the crack tip, crosssectional weakening is avoided. Heat-induced, negatively acting residual stresses and distortions, usually occurring during repair welding, can also be excluded. Therefore, the effectiveness of adhesively bonded CFRP lamellas to enhance the remaining lifetime of fatigue damaged steel structures is examined in a German research project. Selected results are presented in this paper. To characterize the steel, CFRP and adhesive materials, different tests on small scale specimens are carried out. With the help of fatigue tests on CT-samples the remaining fatigue lifetimes of specimens strengthened with adhesively bonded CFRP lamellas is compared to the remaining lifetimes of specimens strengthened by established methods such as drilling the crack tip and repair welding. Based on the evaluation of the crack propagation after the rehabilitation measures, the great potential of adhesively bonded CFRP reinforcements can be deduced. By prestressing the lamellas, the remaining lifetime can generally be increased further. The combination of adhesively bonded CFRP lamellas together with established rehabilitation methods shows a particularly high positive influence on
the remaining lifetime of the CT-specimens.
The influence of an improved strength grading in situ on modelling timber strength properties
(2019)
Numerical analysis and laboratory experiments of lightweight structured sandwich beams made of steel
(2017)
Using special technology it is possible to produce thin steel plates with a 3-D structure - hexagonal staggered pattern. Such sheets find a range of application in automotive and aerospace industry. The question is: Can we use those sheets also for building applications? Therefore their behaviour under external loads has to be studied.
As an example beams with C-section made of structured sheets under concentrated force in the middle of the upper flange are investigated. This article provides information about load capacity of beams, assembled from structured plates with different thickness. Using Abaqus software beams were modelled and deformation fields for each of them were analyzed. To compare computer calculations with actual results, real sized beams made of structured sheets were constructed in laboratory and bending tests were conducted.
The work presents an innovative approach for simulation of welding induced distortions, which allows taking into consideration the local effects of the welding process as well as the global interactions in the structure. The approach bases on an integration of analytical and numerical calculation’s procedures in a hybrid model, realized with the aid of the inherent strain concept. The analytical procedure calculates the shrinkage strain components and area of the plastic deformed zone, caused by welding. The calculated strains are then transferred to the global finite element model in order to predict the distortions and stresses in the structure after every welding stage, as well as their final state. The consideration of welding scenarios, weld sequence, clamping conditions and the assembling stages is done by taking into account the intermediate variation of the strain state during the manufacturing steps.
The article gives the theoretical basis of the analytical model. The consideration of the essential physical relations is put into discussion. The application of the model is illustrated on complex structures. Its reliability and practicability are demonstrated by means of a validation study.
Residual stresses have major influence on the stability of steel members. It is well-known that, due to the differences in manufacturing procedures, the residual stresses for welded and hot – rolled members are rather different. In the same way, despite several studies on residual stresses distribution and magnitude for hot-rolled members were already done, for prismatic and tapered welded I section steel members the investigation is still very scarce. In the current work, an experimental programme on the buckling resistance of tapered members, with different tapering ratios and section heights, was conducted and residual stress measurements were carried out using the sectioning method. Numerical simulations of the heat input during welding were also performed in order to predict the residual stress fields. A statistical analysis of the residual stresses distribution for welded I section members was performed, using the experimental and numerical results, as well as literature data. Systematized information on residual stresses distribution and magnitude was generated and some guidelines for the statistical characterization of residual stresses in welded members were proposed.
This paper presents the analysis of the statistical size effect in steel structural elements using the stochastic finite element (FE) method. The three-dimensional random field theory is applied to simulate the uncertainty of a nonlinear material. The proposed approach, which combines the discrete random field describing the randomness of the material properties via Monte Carlo simulations, is used for computing the bearing capacity variability of the steel structures. In addition, the mapping interpolation method makes it possible to separate the random field mesh and FE model mesh. The three-dimensional random field for the material properties is established according to the yield strength with a lognormal distribution based on reasonable assumptions, and the corresponding random field parameters are studied. Finally, the results of experimental investigation and simulations are compared based on the tensile and bending tests, and they indicate that the statistical size effect cannot be overlooked in S235JR steel structural elements and that the use of stochastic FE in the analysis of the statistical size effect has tremendous potential.
This paper presents the results of theoretical and experimental investigations on the statistical size effect (SSE) of flexural members in steel. The chain of bundle model is developed, which is based on a stochastic material model by Weibull and lognormal distribution. Furthermore, this model is embedded into the finite element method (FEM) software for the analysis of a complicated structure with a stress gradient. In order to determine the stochastic material model parameters, uniaxial tensile tests were carried out based on specimens using the same steel with different sizes. By comparing the experimental and simulation results, the material parameters could be analyzed based on the relationship between the specimen sizes and strength. Moreover, the 3-point and 4-point bending tests were performed and simulated with the developed model. The experimental and simulation results demonstrate that the SSE also exists in the flexural member, and the equivalent yield stress is closely related to the stress distribution and volume of the structure component.
The Influence of Geometrical and Welding Imperfections on the Strength of Stiffened Structures
(2018)
The strength calculation of stiffened plates and shells via finite element simulation has been part of the state of the art for a long time. Geometrical nonlinearities as well as the nonlinear material behavior are considered within the calculation. To simplify, both types of imperfections, geometrical and structural ones, are mostly combined in these strength calculations being considered as equivalent geometrical imperfections. Values for standard cases are included in EN 1993-1-5 in case of plated structures or 1-6 in case of shells. A second possibility is the separate definition of fabrication tolerances and residual stresses, as far as they are known. With increasing complexity of the structure, less information are however available on geometrical and particularly structural imperfections. Nevertheless, by means of a more realistic consideration of these values, the actual ultimate load can be determined significantly more exactly and the performance of high performance steel structures is increased.
In the investigated cases, deformations and stresses arise mainly due to welding. Therefore, the topic of this article is the application of an analytical numerical hybrid model for predicting imperfections induced by welds. This is presented on an example of a stiffened steel structure and a subsequent ultimate load calculation. At the beginning the analytical model, its physical basis as well as the physical interrelationships are introduced and explained. This is followed by the explanation of the coupling procedure between the analytical model and the numerical calculation for the calculation of weld-induced deformations and residual stresses. The significance of the hybrid model is proven by means of a few sample applications. For a realistic determination of the weld imperfections in the investigated stiffened structure, the coupled hybrid model is used afterwards. An ultimate load analysis gives information about the load carrying behavior under axial loading. The results are compared with the results of an ultimate load analysis from a literature example assuming different eigenvalues with different scaling. The results underline the potential additional utilization of load bearing capacity by this new approach.
This paper present the investigation of the statistical size effect in steel structure and the corresponding reliability. This study described the randomness of material properties through two different ways. These two proposed simulation methods, which are an extension and supplement to traditional simulation methods, can effectively simulate the statistical size effect for the tensile and flexural components in steel structures. The test results show that the variations of the yield and tensile strength increase with the decreasing specimen volume. Besides, the structural component strength is not only related to the specimen volume, but also the stress distribution. It is found by studying the influence of statistical size effect on structural reliability that the strength, which is obtained by small specimens through statistical analysis in the laboratory, is no more accurately applicable to large construction. The core idea is that the stochastic material proper-ties are directly embedded in mechanical calculations to develop a more accurate and economical design method for steel structure.
Strength Calculation of Stiffened Structures Taking Into Consideration Realistic Weld Imperfections
(2018)
The topic of this article is the application of an analytical numerical hybrid model for a realistic prediction of imperfections induced by welds. At the beginning, the analytical model, its physical basis as well as the physical interrelationships are explained. This is followed by the explanation of the coupling procedure between the analytical model and the numerical calculation. Afterwards, the coupled hybrid model is applied on the investigated stiffened curved structure for the determination of the weld imperfections. An ultimate load analysis gives information about the load carrying behavior under axial loading. The results are compared against the traditional approach using eigenmode-based imperfections. The comparison underlines the potential additional utilization of load bearing capacity by this new approach.
Die Stadt Wernigerode in Sachsen-Anhalt errichtete im Ortsteil Schierke eine Multifunktionsarena. Am Fuße des Brockens, dem höchsten Berg des Harzes und ganz Norddeutschlands gelegen, fügt sich die offene Überdachung in die vorhandene Topologie nahtlos ein. Das unter Denkmalschutz stehende Natureisstadion, mit seinen bestehenden Natursteinterrassen und einem Schiedsrichterturm aus Holz, wurde baulich so konzipiert, dass die Arena in den Wintermonaten als überdachte Kunsteisbahn und im Sommer als Fläche für Konzerte, Aufführungen und Sportveranstaltungen genutzt werden kann. Eine ganz besondere Herausforderung war die Herstellung und Montage des circa 190m langen geschweißten Stahlrandträgers. Der Hohlkasten besteht aus vier doppelt gekrümmten Blechen und lagert an lediglich zwei Fußpunkten auf. Der zweite Teil des Beitrags befasst sich mit Schweißeigenspannungen an einem ausgewählten Querschnitt der Überdachung.
Imperfektionen, die bei Traglastberechnungen Berücksichtigung finden müssen, haben ihre Ursachen in Herstellungs- und Fertigungstoleranzen oder werden durch das Schweißen und den damit zumeist einhergehenden Nachbehandlungen in den Bauteilen hervorgerufen. Durch die Wärmewirkung des Schweißens entstehen sowohl sehr große Verformungen als auch signifikante Zug und Druckspannungen. Der strukturelle und geometrische Imperfektionsgrad wird somit maßgeblich von der Anzahl und der Lage der Schweißnähte sowie den Schweißparametern bestimmt. Für die Berücksichtigung in Traglastberechnungen ist ein physikalisch fundiertes Modell erforderlich, welches die Schweißimperfektionen schnell und präzise berechnet. Das gekoppelte analytisch numerische Hybridmodell erfüllt diese Kriterien. Die mathematischen Grundlagen des analytischen Modells sowie die Kopplung mit der numerischen Finite-Elemente-Berechnung werden eingangs vorgestellt und die Anwendung zur Berechnung von Verzügen an einer Schiffsektion demonstriert. Darauffolgend wird das Hybridmodell an einer eben und einer gekrümmten versteiften Platte zur Berechnung der Schweißimperfektionen angewendet. Anschließende Traglastberechnungen sowie der Vergleich mit den Ergebnissen unter der Annahme einer geometrischen Ersatzimperfektion in Form des kritischsten Eigenwerts gibt Auskunft darüber, welches Potenzial die realitätsnahe direkte Berücksichtigung von Schweißimperfektionen birgt.
Aktuelle Normen für den Bestandsbau mit Holz und beispielhafte Zuverlässigkeitsuntersuchungen
(2018)
Welded tubular joints are widely used in structural engineering due to their excellent resistance and stiffness, as well as simple connection. However, the welding process induces residual stresses in the welding area that can affect the structural behavior of joints. Currently very few papers investigate welding residual stresses in relation to tubular joints. This paper develops a finite element model of rectangular hollow section T joints considering welding residual stresses. Attention is paid particularly to welding sequences. The developed model is used to evaluate the effect of welding residual stresses on the resistance and initial stiffness of tubular joints. The results show that welding residual stresses increase the plastic resistance of rectangular hollow section joints under in-plane bending and axial brace loading.
Due to the uncertain microscopic structure of the material, the strength of the material exhibits strong randomness. This randomness results in uncertain response of the structure in the sequentially coupled thermal-mechanical analysis by welding simulation. Because of the limitations of deterministic welding simulation, the stochastic finite element method with random field will be introduced into the welding simulation, so that the welded structure can be more accurately calculated in the stability and reliability structural analysis. Particularly, it is necessary to propose reasonable distributions of residual stress from welding simulations based on statistical and reliability theories. This paper is intended to implement the stochastic finite element method in the welding simulation using a general-purpose simulation program and to demonstrate the potential of the proposed approach. Furthermore, the statistical distribution function of the welding simulation response is obtained by maximum entropy fitting method. Then, a numerical example is presented by the proposed method.
Welding residual stresses that occur in tubular joints after the welding process affect their structural behavior. To ensure that these stresses do not negatively act on the load-bearing capacity of joints, their influence should be carefully investigated. This paper represents the second part of a study that numerically evaluates the structural behavior of rectangular hollow section T joints taking into account welding residual stresses. The finite element model developed in Part 1 is now used to evaluate their effect on the resistance and initial stiffness of tubular joints. The conducted parametric analyses show that welding residual stresses have a positive influence of 1–19 % on the plastic resistance of tubular joints and insignificantly reduce their initial stiffness. At the same time, the behavior of the considered joints is found not to depend on the welding sequence.
Тhe development of steel bridges after the WWII is characterized by new constructive forms like: steel roadway closed sections, new static systems considering the roadway as a plate rather than a beam grid, new computational methods covering rod statics and statics of continuum, and determining the internal forces of the roadway as internal forces of an orthotropic plate. Moreover, the main girders, the roadway and the horizontal links connect statically and constructively in a whole monolithic structure. Thus, the construction follows better the real distribution of internal forces in steel structure. Loading possibility of high-quality steel material is well used, by which the economic effect of the construction increases significantly compared to the riveted old bridges. The application of this theory in Bulgaria in the period 1976 – 1992 allowed the Bulgarian bridge construction to build several unique by their size steel road bridges of steel orthotropic decks.
Welded tubular joints are widely used in structural engineering due to their excellent resistance and stiffness in contrast to open sections, as well as simpler end preparation. Welding residual stresses that occur in these joints after the welding process can affect their structural behavior. Some recent experimental studies have shown that this effect can be considerable. This study numerically evaluates the influence of welding residual stresses on the behavior of rectangular hollow section T joints. The paper consists of two parts. Part I develops and validates a finite element model for the joints directly taking into account welding residual stresses by means of an upstream thermomechanical simulation of the welding process. It is proven that particular attention needs to be paid to the discretization of the model, the material properties and the adequate description of the weld heat input. The validation with experimental results shows that the developed numerical model properly captures the local structural behavior of tubular joints and can be efficiently used for further investigations. Part II employs the constructed model to investigate the effect of welding residual stresses on the resistance and initial stiffness of the considered joints.
Die Festigkeitsberechnung von Strukturen, zum Beispiel Platten oder Schalen, mittels der Finite-Elemente-Methode gehört schon seit längerem zum Stand der Technik. Berücksichtigt werden bei der Berechnung sowohl geometrische Nichtlinearitäten als auch das nichtlineare Verhalten des Werkstoffs. Die geometrischen und strukturellen Imperfektionen werden bei der Ermittlung der Festigkeit zumeist in ausschließlich geometrischen Imperfektionen, wie bspw. Kombinationen aus Fertigungstoleranzen und den Ergebnissen von Beulanalysen zusammengefasst. Zur Rechtfertigung dieser Vorgehensweise werden die geometrischen Imperfektionen gemäß DIN EN 1993-1-5 erhöht. In einem Kommentar zur selben Norm findet
sich ebenfalls eine Empfehlung zur Berücksichtigung von Schweißimperfektionen in Form von vereinfachten Längseigenspannungsverläufen. Diese werden in Abhängigkeit der
Fließgrenzspannung des Werkstoffs bei Raumtemperatur und der Dicken der Fügepartner angenommen. Sowohl die Annahme rein geometrischer Imperfektionen als auch die Berücksichtigung vereinfachter Eigenspannungszustände, sind mit Sicherheitszuschlägen
behaftet. Durch eine realitätsnähere Berücksichtigung von strukturellen und geometrischen Imperfektionen, hervorgerufen durch Schweißprozesse, kann die tatsächliche Tragfähigkeit einer Struktur wesentlich exakter bestimmt werden. Inhalt dieses Artikels ist die Anwendung eines analytisch-numerischen Hybridmodells zur
Schweißimperfektionsberechnung an einer doppelt versteiften Platte und einer anschließenden Festigkeitsanalyse. Eingangs wird das analytische Modell vorgestellt und auf die grundlegenden
physikalischen Zusammenhänge eingegangen. Es folgt die Erläuterung des Kopplungsalgorithmus zwischen analytischem Modell und der numerischen Berechnung. Angewendet an der doppelt versteiften Platte, wird ein realitätsnaher geometrischer und
struktureller Imperfektionszustand berechnet. Eine anschließende Traglastanalyse gibt Aufschluss über das Verformungsverhalten unter achsialer Krafteinwirkung. Zur Bewertung der Ergebnisse wird ein Modell gleicher geometrischer Abmessungen und Werkstoffkennwerte aus
der Literatur herangezogen. Berechnet wurden die ersten 6 Eigenformen mittels analytischer und numerischer Modelle sowie die Last-Verformungskurven unter der Annahme unterschiedlicher geometrischer Imperfektionen. Um die Vergleichbarkeit der Ergebnisse zu sichern, wird eingangs die Lagerung des Modells sowie der Kraftangriffspunkt in Längsrichtung invers, durch den Vergleich der ersten 6 Beulformen sowie der Last-Verformungskurven dreier
Imperfektionen, bestimmt. Darauf aufbauen wird die Last-Verformungskurve für einen überlagerten Imperfektionszustand berechnet, wobei die geometrischen Imperfektionen aus den
Fertigungstoleranzen abgeleitet und die strukturellen idealisiert, gemäß DIN EN 1993-1-5, gewählt werden. Abschließend werden alle Last-Verformungskurven einander gegenübergestellt.
Anhand des Vergleichs kann quantifiziert werden, wie konservativ die einzelnen angenommenen Imperfektionen sind und wie sich der Verformungsverlauf darstellt, berechnet man diesen unter
Verwendung realitätsnaher geometrischer und struktureller Imperfektionen.
Ringsteifen werden typischerweise bei dünnwandigen Tanks am Mantel befestigt, um auch für starken Wind und/oder Unterdruck eine ausreichende Beulsicherheit sicherzustellen. Eine Vielzahl an Veröffentlichungen zum Thema Ringsteifen beschäftigt sich ausschließlich mit den vorher genannten Lastfällen. Dagegen ist der traglaststeigernde Einfluss der Ringsteifen im Lastfall Axialdruck kaum erforscht. Experimentell wurde vor allem in den 1960er und 1970er Jahren gegenüber unversteiften Schalen, für eng-ringversteifte ein erheblich verbessertes Tragverhalten nachgewiesen. Der eingeschränkte Parameterbereich der Untersuchungen verhindert jedoch die Anwendung der Erkenntnisse im Metallbau, wo, aufgrund der Fertigungskosten, eher wenige, dafür kräftigere
Ringsteifen eingesetzt werden. Der Beitrag baut auf den experimentellen Studien als Grundlage auf und erweitert die
Erkenntnisse mittels numerischer Parameterstudien von eng-ringversteiften Schalen auf Kreiszylinder mit Steifenabständen bis zum Zehnfachen der klassischen Beulhalbwellenlänge 1.73√rt. Es wird gezeigt, dass auch mit versteiften Schalen, bei denen der Steifenabstand größer als zwei Beulhalbwellenlängen ist, noch
Tragfähigkeitssteigerungen gegenüber der unversteiften Schale erreicht werden können. Erwartungsgemäß sind die Zugewinne an Traglast bei enger versteiften Kreiszylindern am größten, wobei vor allem dünnwandige Strukturen von der verringerten
Imperfektionssensitivität profitieren. Die Ergebnisse, angewandt auf die Baupraxis, erlauben eine wirtschaftlichere Bemessung
von Tanks und Silos mit Ringsteifen, sofern Axialdruck eine bemessungsrelevante Lastsituation darstellt. Dies ist in der Regel bei überdachten Silos und windbelasteten Flachbodentanks der Fall. Dafür ist kein zusätzlicher Konstruktionsaufwand notwendig, da
lediglich die ohnehin vorhandene Struktur vorteilhafter ausgenutzt wird.
For stadium roofs light weight constructions, that are tensioned between a cantilevering steel compression ring, are commonly build around the globe, mostly for social events like sport games and concerts. They allow having no columns in the viewing area and also spanning the whole arena. With the additional use of membranes as the roof shell, the inside of the building will get naturally lighted. With the knowledge of the occurring loads, an economic structure can be found to optimize the edge structure. Frequently the form finding process will use the death loads as decisive action because for only one load case a moment free form can be determined. Other load cases will cause bending in the girder. The process also allows having only supports at the low points and a cantilever arises. These types of roofs will be compared with two exemplary canopies in Germany. The main focus will be on the assembly of the edge girder, which will evoke challenges for planning as well as the actual manufacturing process. The steel edge girder is double curved and has a spatially shape. The welded box exists of 4 to 5 curving plates that have thicknesses from 15mm to 55mm and will vary in their height. Due to welding residual stresses occur during the assembly in the factory as well as on the construction side. For the design of the girders, the residual stresses need to be determined. The identified results of the residual stresses will vary through the plate thickness and will differ for residual longitudinal and residual transverse stresses. The longitudinal residual stresses, as the relevant residual stresses for axial forces, will be farther scrutinized. Due to its complex geometry the challenges of the simulation will be presented for the manufacturing process and the construction site assembly. For the farther investigation the calculated stresses will be taken for a load capacity calculation of a section of the edge girder. Due to the forming geometry and the welding process, both effects need to be considered. This calculation will also show that the edge girder needs to be stiffened in the inside with bulkhead plate’s und longitudinal stiffeners. Both authors are involved in the verification of the objects (Customer Centre in the Autostadt Wolfsburg-CC, Schierke-Arena ‐FA in the Harz Mountains) mentioned below.
Several approaches on geometrical and structural imperfections are given in the literature for I sections and rectangular box girders. Those approximations of the residuals stress state can be implemented into the structural analysis using multi-purpose FEM program packages. The knowledge of the stress state of free forming cross sections has still to be determined. To fulfil a safe design, the assumptions mostly will be very conservative due to the lack of the assumed stress state. This will result directly to increased thicknesses or additional stiffening of the plates. Not only the material cost will rise, but also the fabrication costs like welding will be affected. This paper aims to provide an overview on the possibilities in the numerical prediction of weld residual stresses and weld induced deformations for cross sections with unique shapes. With the obtained values the tendencies of the residual stress state and deformations will be used to optimize the design. A representative example on a section used in a steel compression ring of a realized roof is described and analyzed using a simplification of a numerical welding simulation. The reduced simulation of the originally transient weld procedure was held to a practically reasonable level and can be reproduced for similar problems. The calculations used the Abaqus Welding Interface (AWI) to automate working steps in conjunction with the definition of weld passes and their sequencing. The field of the method that is discussed also a need of further investigations to prove its applicability. Some experimental back up is requires to verify the result quality. Nonetheless, this method could already help to show up tendencies or to identify potential critical spots in the design.
Influence of closely spaced ring-stiffeners on the axial buckling behavior of cylindrical shells
(2017)
Material efficiency in modern tank constructions often is achieved by combining thin plates with light and heavy ring stiffeners. While the plates are designed to resist hydrostatic pressure, the stiffeners are designed against wind and external pressure. Axial buckling may occur due to high roof loads and wind since very thin plates are prone to a loss of stability.
Test results in the 60s and 70s revealed that closely spaced ring-stiffeners may greatly enhance the axial buckling behavior, allowing for knock-down factors greater unity. However, until today, no design procedure is available allowing for adopting the beneficial effect of ring stiffeners under axial compression into practical design.
In this paper a design procedure is proposed that closes this gap in current design codes. One outcome of the conducted literature study revealed that test results of unstiffened shells may be more closely approximated and is shortly presented. The design procedure for ring-stiffened shells was then developed from lower bound curves deduced from categorized buckling tests.
The results of a parametrical study, that was conducted over a wide range of r/t-values, is presented. Imperfection depths up to 10t were examined using a stiffener spacing of one buckling half-wave. Especially highly slender stiffened cylinders benefit from ring-stiffening, showing up to 380% strength gains.
Imperfection depths proposed by the current design code were found to be too conservative.
Major advances in the buckling analysis of cylindrical shells have been achieved in the last two decades. Eurocode nowadays provides rules for tanks up to r/t = 5000. However, since only few literature has become available in the past, dealing specifically with very thin walled shells in the range between r/t = 1500 and r/t = 10000, code provisions either are quite conservative or, in case of r/t > 5000, do barely exist. Employing modern construction methods, close-to perfect, very thin-walled shells can be built that are out of the scope of the design codes. Therefore, to achieve more economical designs and a better sustainability, sophisticated design tools have to be used.
In this paper, modifications and extensions of the current design procedure are proposed to overcome current limitations and drawbacks. A review of experiments with a special focus on cylinders with high r/t-ratios was conducted and modified lower bound approximation curves for the knock-down factor α deduced. They were checked against representative experiments from literature. Test results recalculated using an axisymmetric imperfection to explore their equivalent imperfection depth, proved that even small imperfections drastically reduce the buckling strength. Using a parametric study, the result range of α was extended up to r/t = 10000. The design proposal could be approved and an equation for the determination of an equivalent imperfection depth that relates the dependence of α to the imperfection depth and the r/t-ratio is proposed.
Reliability analysis of size effect on flexural members with stochastic finite element method
(2017)
For standard sections including I-girders and rectangular box girders, several approaches on geometrical and structural imperfections are given in the literature, which can be implemented in a numerical analysis. For complex sections, as found in many of today's lightweight roof structures, these assumptions are conservative due to the sections typically unique shape, which leads to increased thicknesses or additional stiffening of the plates. This, on the other hand, can significantly affect fabrication costs. This paper aims to provide an overview on the possibilities in the numerical prediction of weld residual stresses and weld-induced deformations for these sections. The obtained values can be used in a subsequent numerical analysis to understand the structural behavior and optimize the design. A representative example on a section used in a steel compression ring is described and analyzed using the numerical welding simulation. A simplification of the originally transient weld procedure is used in order to reduce computation times to a practically reasonable level. In this context, the Abaqus Welding Interface (AWI) helps to automate working steps in conjunction with the definition of weld passes and their sequencing, which shall be shown in here. The applicability of this method is discussed showing also a need of further investigations in this field. This is especially with regard to result quality, which requires some experimental back-up. Nonetheless, this method could already help to show up tendencies or to identify potential critical spots in the design.
Weld residual stresses effects in the design of welded plate girders: Simulation and Implementation
(2017)
Eurocode 3 offers different possibilities on a numerically-aided design of welded plate girders. In this, a geometrically and materially nonlinear analysis of the imperfect structure (GMNIA) provides the theoretically highest possible degree of realism. A correct implementation of “imperfections” is of critical importance in the practical application of this method. The current design rules are based on long term experience in terms of traditional (“old”) welding procedures and regular (“low strength”) steel grades. Thus, they provide very approximate (but safe) rules for these structures. With the introduction of modern shop welding operations and materials, many of these assumptions seem to be over-conservative. A revision of these rules is being processed in different national and international research projects. This particular study focusses on the weld residual stresses and their effects in conventional steel S355 and high strength steel S690. Metal active gas (MAG) welding under shop welding conditions was used. The measurement of weld residual stresses on component-like samples (carried out by the BAM Bundesanstalt für Materialforschung und -prüfung in Berlin) has been widely published. The hereupon based (simplified) welding simulation as part of a subsequent structural analysis is shown here. A novel numerical approach how to directly incorporate the results into large structural components models is presented. The capacity analysis is performed on a simple example for weak-axis buckling. The results indicate significant improvements in the utilization of load-bearing capacity and underline the superior buckling assignment for the S690 compared to conventional S355. The experimental validation of the findings is currently being prepared.