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    Fatigue Life Calculation of Weld

    Uploaded by

    Saut Maruli Tua Samosir
    The document summarizes Ahmed Al-Mukhtar's PhD research on calculating fatigue life of welded joints using fracture mechanics. It outlines using finite element analysis software FRANC2D to accurately calculate stress intensity factors for cracks in welded joints. Results show SIF calculations matching empirical solutions and standards. Fatigue life calculations using Paris' law also match standards for some joints but provide new fatigue strength values for joints not covered by standards. The research concludes FRANC2D can accurately model different weld geometries to evaluate fatigue life without expensive experiments.

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    Fatigue Life Calculation of Weld

    Uploaded by

    Saut Maruli Tua Samosir
    284 views15 pages
    The document summarizes Ahmed Al-Mukhtar's PhD research on calculating fatigue life of welded joints using fracture mechanics. It outlines using finite element analysis software FRANC2D to accurately calculate stress intensity factors for cracks in welded joints. Results show SIF calculations matching empirical solutions and standards. Fatigue life calculations using Paris' law also match standards for some joints but provide new fatigue strength values for joints not covered by standards. The research concludes FRANC2D can accurately model different weld geometries to evaluate fatigue life without expensive experiments.

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    Fatigue Life calculation of weld

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    The document summarizes Ahmed Al-Mukhtar's PhD research on calculating fatigue life of welded joints using fracture mechanics. It outlines using finite element analysis software FRANC2D to accurately calculate stress intensity factors for cracks in welded joints. Results show SIF calculations matching empirical solutions and standards. Fatigue life calculations using Paris' law also match standards for some joints but provide new fatigue strength values for joints not covered by standards. The research concludes FRANC2D can accurately model different weld geometries to evaluate fatigue life without expensive experiments.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    284 views15 pages

    Fatigue Life Calculation of Weld

    Uploaded by

    Saut Maruli Tua Samosir
    The document summarizes Ahmed Al-Mukhtar's PhD research on calculating fatigue life of welded joints using fracture mechanics. It outlines using finite element analysis software FRANC2D to accurately calculate stress intensity factors for cracks in welded joints. Results show SIF calculations matching empirical solutions and standards. Fatigue life calculations using Paris' law also match standards for some joints but provide new fatigue strength values for joints not covered by standards. The research concludes FRANC2D can accurately model different weld geometries to evaluate fatigue life without expensive experiments.

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    © All Rights Reserved
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    The key takeaways are that fracture mechanics and finite element analysis (FEA) are used to accurately calculate stress intensity factors (SIF) and fatigue life of welded joints to evaluate fatigue strength.

    The aim of the research is to accurately calculate SIF and fatigue life of welded joints with different geometries not presented in previous recommendations in order to evaluate fatigue strength and save time and costs of experimental testing.

    SIF is calculated through finite element analysis software FRANC2D, which has advantages over other simulations as it is not affected by mesh properties and can model complex crack geometries.

    Institut of Materials Engineering

    PHD Programme

    Fatigue life calculation of welded joints based on fracture


    mechanics

    Ahmed M. Al-Mukhtar*
    MSc. Materials and Manufacturing Engineering
    BSc. Aeronatical Engineering

    Supervisors:

    Prof. Dr.- Ing. habil. H. Biermann*


    Prof. Dr.- Ing. P. Hbner**

    *Institute of Materials Engineering, Technische Universitt Bergakademie Freiberg, Germany


    **Fachhochschule Mittweida, Mittweida, Germany

    Outlines
    1)

    Aim of reaserch (Objectives) - Procedure

    2)

    Introduction (Why fracture mechanics?)

    3)

    Finite Element Analysis (FEA)


    - Modelling
    - Crack path direction

    4)

    Standard and fatigue design recommendations

    5)

    Results (benchmarking)
    - SIF calculation and comparison for some welded joints
    - Fatigue life calculation and comparison for some welded joints
    - Case study not presented in the recommendation

    6)

    Conclusions

    1.1.
    Aim
    andProecdures
    Ziel
    und Aufgabenstellung

    Aim
    - Accurate SIF calculation
    - Moreover, calculate the fatigue life, and the fatigue strength (FAT) of the welded
    joints with different geometries that not presented in recommendations

    Procedures
    1) FE modeling which give accurate stress intensity factor.
    2) With knowledge of the stress intensity factors KI at different crack depths (a), it
    was possible to make curve fits for KI(a) for the different loading and use Paris
    law to integrate numerically and calculate the expected fatigue life for the
    specimens.
    3) Case studies can be consulted, and the need for well thought out benchmarking
    of analytical results against experimental databases-IIW
    3

    2.1.
    Introdcution
    - Why
    Fracure Mechanics?
    Ziel und
    Aufgabenstellung
    - One of the most important deterioration mechanisms of

    Aloha Airlines.1988

    Aircrafts, ships and steel bridge structures which occur in


    service condition is Fatigue.
    - Fatigue Failure, accounts for at least 75% of all machines

    and structures failures


    - Crack normally existed! But may be accelerated due to

    environment and loading condition-A.A. Griffith (18931963)


    De Havilland First commercial jet aircraft
    fatigue cracks initiated at square windows, 1954

    Goal: Calculate ai, which already existed and

    crack growth parameters


    Fatigue life
    calculation and FAT

    Safe life and lower cost


    consuming for experiments
    tests

    2. Introdcution - Why Fracure Mechanics?

    Seven of the Liberty ships built during the world war II has broken completely in two as a
    result of brittle fractures. (1943)

    However, larger safety factor !!

    Crack normally existed !! How long?

    2. Introdcution - Why Fracure Mechanics?


    Fontana Dam, North Carolina, USA

    Ref.Ingraffea A R. Case Studies of Simulation of Fracture in Concrete Dams. Eng. Fracture Mech., 35, 1/2/3, 1990, 553-564.

    3. FRacture ANalysis Code (Finite Element Analysis FEA) Two Dimension


    FRANC2D & CASCA (*)

    FRANC2D is a FE based simulator for


    curvilinear crack propagtion planar
    structures. CASCA which used for the
    creating the meshes, is a preprocessor for
    genrating initial input file for FRANC2D.

    Applicatons

    Civil Engineering (Dams)


    Mechanical Engineering (Welded joints)

    Output

    Stress intensity fcator,SIF(KIC)

    Compare with other FEM sofware


    The results have been shown that FRANC2D
    has advantages over other simulations to
    calculate SIF because there are:

    *-Cornell Fracture Group,

    No effect of, mesh size, densitry distributon


    and those save time and effort.

    Also no problem with badly shaped meshes


    elements have been disapperad.

    http://www.cfg.cornell.edu

    3. FRacture ANalysis Code (Finite Element Analysis FEA) Two Dimension


    Simulation and prediction crack growth in welded and complex structures

    4. Standard and fatigue design recommendations


    - International insitute of Welding-IIW
    - British standards- BS
    - Japanese Society of Steel construction-JSSC

    5. Results
    SIF calculation and comparison
    -Non load carrying joint
    -Cruciform joint load carrying

    45

    800
    700

    40

    Frank,Fisher,Modified
    BS.B=T=15,h=6mm

    35
    SIF (Mpa.m^0.5)

    K (Mpa.mm1/2)

    600

    FRANC2D.B=T=15.h=6

    500
    400
    300

    30
    25
    20
    FRANC2D
    15

    New approach

    10

    200

    100

    10

    3
    Crack length (mm)

    a (mm)

    10

    5. Results
    SIF calculation and comparison
    -Butt weld (V-Butt,incomplete and complete penetration-machined and non machined flash)

    140
    FRANC2D

    120

    Empirical solution.Ref.19

    SIF (Mpa.m1/2)

    100
    80
    60
    40

    20
    0
    0

    Crack length (m m )

    11

    5. Results
    Fatigue life calculation and comparison
    -Non-load carrying cruciform joint.
    -Comparison with IIW. FAT 63 Mpa.

    -Butt weld.
    -Comparison with IIW. FAT 80 Mpa.
    1000

    Stress Range (Mpa.)

    Stress Rang (M pa.)

    1000

    100

    10

    FAT63.IIW

    100

    10

    FRANC2D
    1
    1,E+04

    1,E+05

    FAT80.IIW

    FRANC2D
    1,E+06

    Log N (Cycle)

    1,E+07

    1,E+08

    1
    1,E+03

    1,E+04

    1,E+05

    1,E+06

    1,E+07

    1,E+08

    Log N (Cycle)

    12

    1,E+09

    1,E+10

    5. Results
    -New Geometry not presenetd in IIW recommendations
    -Fatigue life calculation and comparison
    provided a new value of FAT could be considered as the design value or lower bound.
    The new case with fillet radius not consider in IIW and in BS. (FAT=71 Mpa.)
    1000

    Radius Rt

    Stress Rang (Mpa.)

    100

    Experimental

    10

    FAT63.No toe radius.IIW

    FRANC2D.C=5E13.m=3.ai=0.1mm.with toe radius


    C=1,85E-13.m=3.mean values

    1
    1,E+04

    1,E+05

    1,E+06

    1,E+07

    Log N (Cycle)

    13

    1,E+08

    6. Conclusions

    1) Accurate SIF is calculated through FEM FRANC2D


    2) Different weld geometries which are not yet listed in
    previous recommendations could be easily modeled to
    evaluate the fatigue life strength. Which means that,
    2) The new approach saves the time and costs need for
    experimental testes

    14

    Thank you for your attention

    Vielen Dank fr Ihre Aufmerksamkeit

    15

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