Professional Documents
Culture Documents
Aditya Sakhalkar
5/8/2007
Background
Why The Battelles Structure Stress Is Not Sensitive To FE Mesh
Size?
Background
Its been commonly recognized that the fatigue life of the polished
specimen is dominated by fatigue crack initiation, whereas that of
welded structures is dominated by small crack propagation from some
pre-existing discontinuity.
da
C (K)n
dN
(1)
For a flaw size starts from a0 to a critical fatigue crack size af, the remaining
fatigue life N under stress range S is obtained by integrating Eq (1):
af
a0
da
C N
n
(K)
(2)
ps
x
A
t (Structural Stress)
0.4 t
t
(b) Comparison of SCF predicted by various modeling
procedures and extrapolation based HSS at the weld toe [12].
0 FE
(Human Factor )
FE
Hot Spot
No min al
X
~0.4 t
(a) Normal Stress at the sharp corner
Y
X
(a)
P2
P1
Fy
P2
Fx
Neutral axis
t
tm
tb
P1
P1
P2
(b)
(t )
m/
N/
(tm )
P2
(tb )
P1
Q/
P2
(tm )=
N
A
(tb )=
m
W
Shell Element:
i. Calculate nodal force ( N/, m/, Q/ )
ii. Calculation of structural stress
Because equilibrium has to be satisfied
Thus: m/=m
Q/=Q And
t /
t
t /
t
/
m
m
b
b
N =N
(b)
(c)
Equivalent SS Method
Different factors may attribute to short crack anomalous growth such as the effect of crack
closure, micro structure interaction and that of notch details.
A unified SIF formulation for both short and long crack and a two stage crack propagation model
were proposed by Dr. Dong & his coworkers, Battelle, to use Equivalent Structural Stress as a
parameter for weldments fatigue life assessment.
A
1
t1
(a)
(b)
A R2
(c)
2
x
R1
t1/t=0.1
1
t1
t
t1
(d)
(f)
(e)
=
/
x
= /x - t
(a) Weld geometry with a hypothetical crack l ; (b) Actual normal stress distribution; (c)
Simplification; (d) Decomposition; (e) Equilibrium-equivalent structural stress or far-field
stress; (f) Self-equilibrating stress (notch stress) with respect to a reference depth t1.
t1
t
3
(a)
(b)
K = K n (t ) K s ()
(0 l t)
(c)
Notch Stress
Structural Stress, Far field stress
The drive force for crack to start and grow is the crack tip stress, introduce crack
surface traction ps called self equilibrating surface traction due to (notch effect)
ps
ps = f( )
= f( , t x/ )
(e)
(d)
t1
x
3
K s () K s (ps ) K s ( , )
t
/
x
(0 l t )
l
t
(d)
K = K n (t ) K s (ps )
(e)
l
t
(f)
(0 l t )
Notch Effect
Structural Stress, Far field stress
Notch Effect
Notch Effect
(0 l t )
K = Mkn K n (t )
(0 l t)
(0 l t)
a/t
a/t
Comparisons of stress intensity magnification factor Mkn at 135 sharp V notch for various
specimen geometries and loading conditions: (a) Edge crack solutions; (b) Elliptical crack
solutions for a/c = 0.4
a/t
a/t
Conclusions:
Mkn approaches unity as crack size a/t approaches 0.1 i.e., a/t=0.1 (short
crack correction factor) Thus a/t=0.1 can be taken as a characteristic
parameter beyond which the notch effect is negligible
The difference between edge crack and elliptical crack solutions are not
significant.
(b)
s C t
1
m
I(r) N
1
m
(e)
(d)
Equivalent SS Method
Summary
The Structural Stress Method developed at Battelle is
mesh insensitive that removes the uncertainty in the
calculation of structural stress for weld joint fatigue
assessment
References
[1]. BS PD 5500: , BSI Standards, London, 2000.
[2]. European Standard for Unfired Pressure Vessels, EN 13445: 2002, BS EN 13445:2002, BSI, London, 2002
[3]. ASME Boiler and Pressure Vessel Code, Section VIII, Rules for construction of pressure vessels, Division 2Alternative rules, ASME, 2003.
[4]. Carl E. Jaske, FSRF for WPVP, Journal of Pressure Vessel Technology, AUGUST 2000, Vol. 122, 297-304
[5]. S.J.Maddox, Review of fatigue assessment procedures, Int. J. of Fatigue, Vol. 25, 12, 2003, 1359-1378.
[6]. Maddox S J: 'Fatigue aspects of pressure vessel design, Spence J and Tooth A S, E & F N Spon, London, 1994.
[7]. Harrison J D and Maddox S J: 'A critical examination of rules for the design of pressure vessels subject to fatigue
loading' in Proc. 4th Int. Conf. on 'Pressure Vessel Technology', Mech E, London, 1980.
[8]. Taylor N (Ed): 'Current practices for design against fatigue in pressure equipment', EPERC Bulletin No.6, European
Commission, NL-1755ZG, Petten, The Netherlands, 2001.
[9]. Dong, P., 2005, A Robust Structural Stress Method for Fatigue Analysis of Offshore/Marine Structures, Journal of
Offshore Mechanics and Arctic Engineering , Vol. 127, pp. 68-74.
[10]. Dong, P., 2001, A Structural Stress Definition and Numerical Implementation for Fatigue Evaluation of Welded
Joints, Int. J. Fatigue, 23/10, pp. 865876.
[11]. Dong, P., Hong, J. K, Osage, D., and Prager, M., Assessment of ASMEs FSRF Rules for Pipe and Vessel Welds
Using A New Structural Stress Method, Welding In the World, Vol. 47, No. 1/2, 2003, pp. 3143.
[12] Dong, P., Hong, J. K., Osage, D., Prager, M., 2002, Master S-N Curve Method for Fatigue Evaluation of Welded
Components, WRC Bulletin, No. 474, August.
[13]. Lankford, J. , Fatigue of Eng Mater and Structures 5 (1982), pp233-248
[14]. R. Craig McClung, et al, Behavior of Small Fatigue Cracks, ASME, Vol. 19, Fatigue & Fracture, P153
[15]. Fricke W., 2001, Recommended Hot-Spot Analysis Procedure for Structural Details of FPSOs and Ships Based on
Round-Robin FE Analysis, ISOPE Proceedings, Stavanger, Norway, June.
Background
ANSYS, Verity, Fe-Safe Weld Assessment Procedure
ANSYS Preprocessing
Verity Analysis
Fe-Safe Analysis
ANSYS Results
Comparison of Analysis Results with the Test Results
Conclusions
Background
Resistance welded suction fitting
Three failures in the suction fitting weld
during reliability testing
Crack initiated at the weld toe (9 o clock)
and propagated through the shell.
Calibration
Quantify loading
relative to the test
for FEA
- Apply load
- Solution
Reliability Testing
Suction Fitting
Shell
Weld Line
ANSYS Results
Maximum Stress
Equivalent Stress
eq
Verity Procedures
Conclusions