m.e thesis_ref.docx

8/15/2019 M.E Thesis_Ref.docx

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DESIGN AND ANALYSIS OF BOLTED JOINTS ON THEBASEFRAME OF A GENSET

MASTER OF ENGINEERING(CAD/CAM)

BYAQHEEL MURTUZA SIDDIQUI

(1604-12-765-015)

MUFFAKHAM JAH COLLEGE OF ENGINEERING AND TECHNOLOGY(Affiliated t O!"a#ia U#i$e%!it&)

H&de%a'ad ***+,-*.,


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DESIGN AND ANALYSIS OF BOLTED JOINTS ON THEBASEFRAME OF A GENSET

A di!!e%tati # t t e O!"a#ia U#i$e%!it& i# f % t e 0a%tial f1lfill"e#t f t e %e21i%e"e#t f % t e a3a%d f t e de4%ee

MASTER OF ENGINEERING(CAD/CAM)

BYAQHEEL MURTUZA SIDDIQUI

(1604-12-765-015)

U#de% t e G1ida#5e f DR 6 N6 SEETHARAMAIAH

C %di#at % Me5 a#i5al De0a%t"e#t

MUFFAKHAM JAH COLLEGE OF ENGINEERING AND TECHNOLOGYR ad # 6+7 Ba#8a%a Hill!7 H&de%a'ad ***+,

(Affiliated t O!"a#ia U#i$e%!it&)


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CERTIFICATE

T i! i! t 5e%tif& t at t e di!!e%tati # 3 %9 titled :DESIGN AND ANALYSIS OFBOLTED JOINTS ON THE BASEFRAME OF A GENSET;7 !1'"itted '& AQHEELMURTUZA SIDDIQUI (1604-12-765-015) 7 a !t1de#t f De0a%t"e#t f Me5 a#i5alE#4i#ee%i#47 M1ffa9 a" Ja C lle4e f E#4i#ee%i#4 a#d Te5 # l 4&7 H&de%a'ad7 affiliated

t O!"a#ia U#i$e%!it&7 i# 0a%tial f1lfill"e#t f % t e a3a%d f t e de4%ee f Ma!te% f E#4i#ee%i#4 i# Me5 a#i5al E#4i#ee%i#47 3it CAD/CAM a! !0e5iali C %di#at %)


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A, NO LEDGEMENT

I 5 #!ide% t i! a! a# 00 %t1#it& t e?0%e!! "& 4%atit1de t all t !e 3 a$e 'ee#

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t e d1%ati # f t i! 0% 8e5t6 He 0% $ided a 3ealt f e?0e%ti!e f% " a di$e%!e 'a594% 1#d f

%e!ea%5 7 a00li5ati # f t e %& i# additi # t 0% $idi#4 "e e#5 1%a4e"e#t t % 14 1t "&

t e!i! 3 %96

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0% $idi#4 %e! 1%5e! #eeded f % "& 0% 8e5t a#d el0i#4 "e 1t 3 e# I it 5% !!% ad! d1%i#4

"& d1%ati # i# t e 5 "0a#&6 I 3 1ld al! li9e t t a#9 M%6 @i#a& S a#9a% a#d M%6 K%i! #a

f % tea5 i#4 "e t e 'a!i5! 3 i5 3e%e e!!e#tial i# 1#de%!ta#di#4 t e 0% 8e5t6

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AQHEEL MURTUZA SIDDIQUI

1


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(1604-12-765-015)

ABSTRA,T

A die!el 4e#e%at % i! t e 5 "'i#ati # f a die!el e#4i#e 3it a# ele5t%i5 4e#e%at %

( fte# a# alte%#at %) t 4e#e%ate ele5t%i5al e#e%4&6 A 4e#!et i! ! %t f % a 4e#e%ati#4 !et6 Die!el

4e#e%ati#4 !et! a%e 1!ed i# 0la5e! 3it 1t 5 ##e5ti # t t e 0 3e% 4%id7 a! e"e%4e#5& 0 3e%

!100l&6 A#& 4e#!et "a#1fa5t1%e% 3a#ti#4 t 4et i#t t e 4e#!et a%e#a %e21i%e! a fail !afe7

e5 # "i5al &et effi5ie#t de!i4# t 5 "0ete 3it it! 5 #te"0 %a%ie!6

T e "ai# !1' a!!e"'lie! i# a 4e#!et a%e Ca# 0&7 E#4i#e7 Alte%#at %7 a#d Ba!ef%a"e6

T e 'a!ef%a"e i! a %e5ta#41la% a!!e"'l& # 3 i5 all t e t e% !1' a!!e"'lie! a%e fi?ed 3it

' lt!6 T e ' lt! a%e t 1! t e #l& t i#4! 3 i5 a%e %e!0 #!i'le f % t e i#te4%ati # f t e

a!!e"'lie!6 Fail1%e f t e!e ' lt! "a& %e!1lt i# di!i#te4%ati # f t e !t%15t1%e6

T a$ id fail1%e7 i# de0t !t1d& i! d #e a! t 3 at fa5t %! 5 #t%i'1te t t e 4%i00i#4

!t%e#4t f ' lt! a#d 3 at a%e t e %ea! #! f % t e fail1%e f ' lted 8 i#t!6 Afte% fi#ali


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,ONTENTS

.RELIMINARIES .AGE NO!

ABSTRACT

LIST OF FIGURES

LIST OF TABLES

.6 INTRODUCTION *.

.6. I#t% d15ti # t B lted J i#t *.

.6- B lt De!5%i0ti # *-

.6+ B lt Sta#da%d! *

.6, B lt Fail1%e! *

.6 Ge#!et! *

.6 C1%%e#t %9 .*

-6 LITERATURE RE@IE .-

-6. A#al&ti5 M deli#4 A00% a5 e! .

-6- FEA Ba!ed E"0i%i5al A00% a5 e! .

+6 METHODOLOGY .

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+6. =% d15t De$el 0"e#t C&5le f % N=I .

+6- B lted J i#t Be a$i % -,

+6-6. St%e!! C #5e#t%ati #! -,

+6-6- Te#!ile St%e!! A%ea -

+6+ Mate%ial! -

+6, Stiff#e!! a#d St%ai# C #!ide%ati #! -

+6 Ti4 te#i#4 T e J i#t +.

+6 T e J i#t i# Se%$i5e +

+6 J i#t Fail1%e ,.

,6 COM=UTATIONAL STUDY ,+

,6. I#t% d15ti # T C "01te% Aided De!i4# (CAD) ,+

,6- H&0e%Me! ,,

,6-6. Be#efit! f H&0e%Me! ,,

,6-6- Ca0a'ilitie! f H&0e%Me! ,

,6-6+ FE M deli#4 f Ge#!et Ba!e F%a"e ,

,6+ ABA US

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,6+6. Feat1%e! f A'a21!

,6+6- A'a21! A#al&!i! Se21e#5e

6 RESULTS AND DISCUSSIONS .

REFERENCES .

5


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LIST OF FIGURES

Fi4 .6. U#ified a#d ISO T %ead Ge "et%&Fi4 .6- N "e#5lat1%e F % S0e5if&i#4 A T %eaded Fa!te#e%

Fi4 .6+ Fail1%e l 5ati #! i# B lt

Fi4.6, Fail1%e i# Fa!te#ed Me"'e%!

Fi4 .6 Fail1%e a! a Ca1!e f O$e%l ad

Fi4 .6 @ie3 f a Failed Tie R d E#d B lt

Fi4 .6 Ma i#d%a Ge#!et .*

Fi4 -6. A T&0i5al B lted C ##e5ti # .-

Fi4 -6- Re0%e!e#tati # f B lt! a#d J i#t Be a$i#4 a! S0%i#4! .+

Fi4 -6+ A Si"0le J i#t Dia4%a" .

Fi4 -6, J i#t Dia4%a" Afte% T e J i#t i! Cla"0ed B& A B lt .

Fi4 -6 J i#t Dia4%a" Afte% L ad i! A00lied .

Fi4 +6. =% d15t De$el 0"e#t C&5le f % Ne3 =% d15t I#t% d15ti # .

Fi4 +6- A! 9 Le&la#d Ge#!et (,* K@A) a#d E#4i#e a#d Alte%#at % M 1#ti#4! -*

Fi4 +6+ C1""i#! Ja9! # Ge#!et ( * K@A) A#d E#4i#e A#d Alte%#at % M 1#ti#4! -.

Fi4 +6, Da"a? Ge#!et (,* K@A) A#d E#4i#e A#d Alte%#at % M 1#ti#4! --

Fi4 +6 St%e!! C #5e#t%ati # # @a%i 1! L 5ati # f B lt i# a J i#t -

Fi4 +6 St%e!! Le$el! i# T %ee Diffe%e#t N1t! -

Fi4 +6 Te#!ile St%e!! St%ai# Dia4%a" -

Fi4 +6 R d f 1#if %" dia"ete%7 l aded i# te#!i # a#d e21i$ale#t !0%i#4 " del -

Fi4 +6 T%21e a#d T1%# =% 5ed1%e +,

Fi4 +6.* St%et5 C #t% l +

Fi4 +6.. Belle$ille a! e%! +

Fi4 +6.- Ti4 te#i#4 Se21e#5e +

Fi4 ,6. 1alit& C%ite%ia f 1ad A#d T%ia Ele"e#t! ,

Fi4 ,6- C #e f C "0%e!!i # ,

Fi4 ,6+ M deled N1t7 B lt a#d a! e% *

Fi4 ,6, C #e f C "0%e!!i # # B t A'1t"e#t! *

Fi4 ,6 E"'ed"e#t f S lid a#d S ell Ele"e#t! .

Fi4 ,6 C #ta5t! -

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Fi4 ,6 C%eati # f Ri4id +

Fi4 ,6 =%ete#!i # a#d Ma!! A00li5ati # # Ba!e F%a"e +

Fi4 ,6 =% $idi#4 B 1#da%& C #diti #! ,

Fi4 ,6.* =% $idi#4 Di!t%i'1ted L ad!

Fi4 ,6.. =% $idi#4 C #!t%ai#t! # E#ti%e Ba!e f Ba!e F%a"e

Fi4 ,6.- C #!t%ai#t! # O#e =a%t f Ba!e F%a"e

Fi4 ,6.+ De4%ee f F%eed "

Fi4 ,6., A'a21! A#al&!i! Se21e#5e

Fi4 6. G%a0 f % =e%5e#ta4e S ea% Ca0a5it& f % M.- ' lt! +

Fi4 6- "ed G%a0 f =e%5e#ta4e S ea% Ca0a5it& f % M.- B lt +

Fi4 6+ G%a0 f % =e%5e#ta4e S ea% Ca0a5it& f % M.* ' lt! ,

Fi4 6, "ed G%a0 f =e%5e#ta4e S ea% Ca0a5it& f % M.* B lt ,

Fi4 6 G%a0 f % =e%5e#ta4e Sli0 f % M.- ' lt!

Fi4 6 "ed G%a0 f =e%5e#ta4e Sli0 f % M.- B lt

Fi4 6 G%a0 f % =e%5e#ta4e Sli0 f % M.* ' lt!

Fi4 6 "ed G%a0 f =e%5e#ta4e Sli0 f % M.* B lt

Fi4 6 Ba!e F%a"e =l t

Fi4 6.* Se5ti # @ie3 f M.- B lt! it A'1t"e#t!

Fi4 6.. Se5ti # @ie3 f M.* B lt! it A'1t"e#t!

Fi4 6.- Fi#al A!!e"'led Ge#!et

Fi4 6.+ B lt! H ldi#4 E#4i#e *

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LIST OF TABLES

Ta'le +6. Clea%a#5e H le! f % Diffe%e#t Dia"ete%! -,

Ta'le +6- N1t Fa5t %! ++

Ta'le +6+ Te#!ile St%e!! A%ea7 =%el ad7 T %21e @al1e! F % Diffe%e#t Met%i5 B lt! ++

Ta'le 6. S ea% Ca0a5it& $al1e! i# 0e%5e#ta4e 'tai#ed f% " a'a21! %e!1lt! .

Ta'le 6- Sli0 $al1e! i# 0e%5e#ta4e 'tai#ed f% " a'a21! %e!1lt! -

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C a0te% .

I#t% d15ti #


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1! INTRODU,TION

1!1 I/# #' / # B +#" J '/#

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fa!te#i#4 a#d a4ai# fa!te#ed f % # ti"e!)7 " !t 5 "" #l& %i$eti#4 a#d ' lti#4 i! 5 !e#6

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t at 8 i#t7 1!1all& de0e#d! # t e 5 %%e5t 5la"0i#4 f %5e 3 i5 ld! t e 0a%t! t 4et e%6

T e A"e%i5a# I#!tit1te f Steel C #!t%15ti # (AISC) !0e5ifie! t e %e21i%e"e#t! f %

' lted !t%15t1%al 5 ##e5ti #!6 St%15t1%al ' lt! %e0la5ed %i$et! d1e t de5%ea!i#4 5 !t a#d

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t&0e! f 8 i#t! !li0 5%iti5al 5 ##e5ti #! a#d 'ea%i#4 5 ##e5ti #!6 I# !li0 5%iti5al 5 ##e5ti #!7

" $e"e#t f t e 5 ##e5ted 0a%t! i! a !e%$i5ea'ilit& 5 #diti # a#d ' lt! a%e ti4 te#ed t a

"i#i"1" %e21i%ed 0%ete#!i #6 Sli0 i! 0%e$e#ted t % 14 f%i5ti # f t e fa&i#4 !1%fa5e7

3 i5 i! t e 0la#e f ! ea% f % t e ' lt a#d 3 e%e t3 "e"'e%! "a9e 5 #ta5t6 Be5a1!e

f%i5ti # i! 0% 0 %ti #al t t e # %"al f %5e7 5 ##e5ti #! "1!t 'e !i


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1!2 B +# D"3 ' #' /

B lt i! a f %" f t %eaded fa!te#e% 3it a# e?te%#al "ale t %ead6 B lt! a%e t 1! 5l !el&

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t1%#ed d1%i#4 a!!e"'l& a#d 3 i5 5a# 'e ti4 te#ed % %elea!ed #l& '& t %21i#4 a #1t i! a

' lt6

D' " "/#'%#' / B"# ""/ B +# A/ S "

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T e di!ti#5ti # 'et3ee# a ' lt a#d a !5%e3 i! 1!1all& 1#5lea% a#d "i!1#de%!t d6

T e%e a%e !e$e%al 0%a5ti5al diffe%e#5e!7 '1t " !t a$e ! "e de4%ee f $e%la0 'et3ee# ' lt!

a#d !5%e3!6

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5 #t%a!t a%e 1!ed 3it 5 "0 #e#t! t at a$e at lea!t #e 5 #tai#i#4 it! 3# t %ead6

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d 3el6 T e 0%e!e#5e f t e 1#t %eaded ! a#9 a! fte# 'ee# 4i$e# a! 5 a%a5te%i!ti5 f ' lt!

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f %"! it! 3# t %ead i# t e 5 "0 #e#t 'ei#4 fa!te#ed7 it i! a !5%e36 T i! i! " !t '$i 1!l& !

3 e# t e t %ead i! ta0e%ed (i6e6 t%aditi #al 3 d!5%e3!)7 0%e5l1di#4 t e 1!e f a #1t6

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0la5e d1%i#4 a!!e"'l&7 eit e% '& a t l % '& a de!i4# f # # % tati#4 ' lt7 !15 a! a 5a%%ia4e

' lt7 a#d #l& t ei% #1t i! t1%#ed6

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B +# H"% 3

B lt! 1!e a 3ide $a%iet& f ead de!i4#!7 a! d !5%e3!6 T e!e a%e de!i4#ed t e#4a4e3it t e t l 1!ed t ti4 te# t e"6 S "e ' lt ead! i#!tead l 59 t e ' lt i# 0la5e7 ! t at it

d e! # t " $e a#d a t l i! #l& #eeded f % t e #1t e#d6

T e fi%!t ' lt! ad !21a%e ead!7 f %"ed '& f %4i#46 T e!e a%e !till f 1#d7 alt 14

"15 " %e 5 "" # t da& i! t e e?a4 #al ead6 T e!e a%e eld a#d t1%#ed '& a !0a##e% %

3%e#5 7 f 3 i5 t e%e a%e "a#& f %"!6 M !t a%e eld f% " t e !ide7 ! "e f% " i# li#e 3it

t e ' lt6

Ma#& !5%e3! 1!e a !5%e3d%i$e% ead fitti#47 %at e% t a# a# e?te%#al 3%e#5 6

S5%e3d%i$e%! a%e a00lied i# li#e 3it t e fa!te#e%7 %at e% t a# f% " t e !ide6 T e!e a%e !"alle%

t a# " !t 3%e#5 ead! a#d 5a## t 1!1all& a00l& t e !a"e a" 1#t f t %21e6 It i! ! "eti"e!

a!!1"ed t at !5%e3d%i$e% ead! i"0l& a !5%e3 a#d 3%e#5 e! i"0l& a ' lt7 alt 14 t i! i!

i#5 %%e5t6 C a5 !5%e3! a%e la%4e !21a%e eaded !5%e3! 3it a ta0e%ed 3 d!5%e3 t %ead7

1!ed f % atta5 i#4 i% #3 %9 t ti"'e%6

Head de!i4#! t at $e%la0 ' t a%e t e Alle# % T %? ead! e?a4 #al % !0li#ed! 59et!6 T e!e " de%# de!i4#! !0a# a la%4e %a#4e f !i


16/95

Ulti"ate te#!ile !t%e#4t i! t e !t%e!! at 3 i5 t e ' lt fail!6 Te#!ile &ield !t%e#4t i!

t e !t%e!! at 3 i5 t e ' lt 3ill %e5ei$e a 0e%"a#e#t !et (a# el #4ati # f% " 3 i5 it 3ill # t

%e5 $e% 3 e# t e f %5e i! %e" $ed) f *6- ff!et !t%ai#6 e# el #4ati#4 a fa!te#e% 0%i % t

%ea5 i#4 t e &ield 0 i#t7 t e fa!te#e% i! !aid t 'e 0e%ati#4 i# t e ela!ti5 %e4i # 3 e%ea!

el #4ati # 'e& #d t e &ield 0 i#t i! %efe%%ed t a! 0e%ati#4 i# t e 0la!ti5 %e4i #7 !i#5e t e

fa!te#e% a! !1ffe%ed 0e%"a#e#t 0la!ti5 def %"ati #6 Mild !teel ' lt! a$e 0% 0e%t& 5la!! ,6 6

Hi4 !t%e#4t !teel ' lt! a$e 0% 0e%t& 5la!! 6 % a' $e6

T e !a"e t&0e f !5%e3 % ' lt 5a# 'e "ade i# "a#& diffe%e#t 4%ade! f "ate%ial6 F %

5%iti5al i4 te#!ile !t%e#4t a00li5ati #!7 l 3 4%ade ' lt! "a& fail7 %e!1lti#4 i# da"a4e %

i#81%&6 O# SAE !ta#da%d ' lt!7 a di!ti#5ti$e 0atte%# f "a%9i#4 i! i"0%e!!ed # t e ead! t

all 3 i#!0e5ti # a#d $alidati # f t e !t%e#4t f t e ' lt6 H 3e$e%7 l 3 5 !t 5 1#te%feitfa!te#e%! "a& 'e f 1#d 3it a5t1al !t%e#4t fa% le!! t a# i#di5ated '& t e "a%9i#4!6 S15

i#fe%i % fa!te#e%! a%e a da#4e% t life a#d 0% 0e%t& 3 e# 1!ed i# ai%5%aft7 a1t " 'ile!7 ea$&

t%159!7 a#d !i"ila% 5%iti5al a00li5ati #! 6

M%#" '%+3

S5%e3! a#d ' lt! a%e 1!1all& "ade f !teel6 e%e 4%eat %e!i!ta#5e t 3eat e% %

5 %% !i # i! %e21i%ed7 li9e i# $e%& !"all !5%e3! % "edi5al i"0la#t!7 "ate%ial! !15 a!!tai#le!! !teel7 '%a!!7 tita#i1"7 '% #


17/95

T e%e i! # #e fa!te#e% "ate%ial t at i! %i4 t f % e$e%& e#$i% #"e#t6 Sele5ti#4 t e

%i4 t fa!te#e% "ate%ial f% " t e $a!t a%%a& f t !e a$aila'le 5a# 'e a da1#ti#4 ta!96 Ca%ef1l

5 #!ide%ati # "1!t 'e 4i$e# t !t%e#4t 7 te"0e%at1%e7 5 %% !i #7 $i'%ati #7 fati41e7 a#d "a#&

t e% $a%ia'le!6 H 3e$e%7 3it ! "e 'a!i5 9# 3led4e a#d 1#de%!ta#di#47 a 3ell t 14 t 1t

e$al1ati # 5a# 'e "ade6 M !t fa!te#e% a00li5ati #! a%e de!i4#ed t !100 %t % t%a#!"it ! "e

f %" f e?te%#all& a00lied l ad6 If t e !t%e#4t f t e fa!te#e% i! t e #l& 5 #5e%#7 t e%e i!

1!1all& # #eed t l 9 'e& #d 5a%' # !teel6 C #!ide%i#4 t e 5 !t f %a3 "ate%ial!7 # #

fe%% 1! "etal! ! 1ld 'e 5 #!ide%ed #l& 3 e# a !0e5ial a00li5ati # i! %e21i%ed6

1! B +# S#%/ % 3

ile !ele5ti#4 a ' lt7 t e%e a%e $a%i 1! !ta#da%d ' lt! a$aila'le i# t e i#d1!t%&6 T e

!ta#da%d! a$aila'le a%e

UNC U#ified Nati #al C a%!e

UNF U#ified Nati #al Fi#e

UNEF U#ified Nati #al E?t%a Fi#e

UNS U#ified Nati #al S0e5ial

UNR U#ified Nati #al R 1#d (% 1#d % t)

ISO I#te%#ati #al Sta#da%d! O%4a#i


18/95

Fi4 .6. U#ified a#d ISO T %ead Ge "et%&

T e %e0%e!e#tati # f t e !ta#da%d ' lt i! # t t e !a"e f % all !ta#da%d!6 T e

# "e#5lat1%e f % !0e5if&i#4 a t %eaded fa!te#e% i! 4i$e# 'el 3 f % U#ified Nati #al a#d

Met%i5 !0e5ifi5ati #! 3it a# e?a"0le i# fi41%e .6- 'el 3

Fi4 .6- N "e#5lat1%e F % S0e5if&i#4 A T %eaded Fa!te#e%

1!4 B +# F%'+ "3

B lt! "a& 'e !1'8e5ted t t 1!a#d! f 0 1#d! f te#!ile f %5e a! 3ell a! alte%#ati#4

f %5e! at a %a#4e f f%e21e#5ie!6 e# a t %eaded fa!te#e% 5a## t !1!tai# t e e?0e5tedl adi#4 a#d 'e5 "e! deta5 ed7 a !i4#ifi5a#t l !! "a& 551%6 T e fail1%e "a& 551% i# ' lt

6


19/95

it!elf a! ! 3# i# fi41%e .6+ % it "a& a00e# i# fa!te#ed "e"'e%! a! ! 3# i# fi41%e .6,

'el 36

Fi4 .6+ Fail1%e l 5ati #! i# B lt

Fi4.6, Fail1%e i# Fa!te#ed Me"'e%!

T e 5a1!e! f t e fail1%e f a ' lted 8 i#t "a& 'e 'e5a1!e f !e$e%al %ea! #!6 S "e f

t e " !t 5 "" # 5a1!e! f fail1%e a%e li!ted 'el 36

F%'+ " A3 A R"3 +# O8" + %

Ma#& a55ide#t! 5a# 'e 5 a%a5te%i


20/95

Fi4 .6 Fail1%e a! a Ca1!e f O$e%l ad

F%'+ " F & L% 9 L 9'/: M" $%/'3&

I# %de% t 0%e$e#t ' lt! f% " l !e#i#4 $e% ti"e7 $a%i 1! l 59i#4 "e5 a#i!"! a%e

e"0l &ed6 T e& i#5l1de l 59 3a! e%!7 l 59i#4 #1t!7 8a" #1t!7 "e5 a#i5al def %"ati #!7 3i%e

3%a07 5 tte% 0i#!7 "etal l 59!7 e?0a#!i # a#5 %!7 eli5al 5 il! a#d 0 l&"e% l 59i#4

5 "0 1#d!6 Ma5 i#e%& t at i! !1'8e5t t $i'%at %& e#$i% #"e#t! 1!1all& i! e21i00ed 3it

! "e ! %t f l 59i#4 "e5 a#i!"6 If t e l 59i#4 "e5 a#i!" i! # t a00lied t t e "a5 i#e%&

d1%i#4 "a#1fa5t1%e7 a 5ata!t% 0 i5 e$e#t "a& %e!1lt6

M"#%+ F%#': "

Metal fati41e i! t e 0 e# "e# # 5 a%a5te%i


21/95

T e ' lt faili#4 i# t e t %eaded !e5ti # at a ! ea% 0 i#t i# t e '%a59et i! 4e#e%all&

5 #!ide%ed 0 % de!i4# t all 3 !i4#ifi5a#t alte%#ati#4 ! ea% % 'e#di#4 f %5e! i# t e $i5i#it&

f t e t %eaded !e5ti # f t e ' lt !i#5e t e t %ead! f %" a !t%e!! %i!e% a#d te#d t i#itiate

fati41e 5%a59!6

F%'+ " F & I& " M%/ % # "

Fi41%e .6 i! a $ie3 f a failed tie % d e#d ' lt7 a 5%iti5al !tee%i#4 !&!te" 5 "0 #e#t

i# a# a1t " 'ile6 T e $e i5le !1dde#l& 01lled t t e %i4 t afte% t%a$eli#4 $e% a '1"0 i# t e

% ad6 T e f%a5t1%e !1%fa5e %e$ealed a# a%ea f 0% 4%e!!i$e f%a5t1%e t at ad 'ee# 551%%i#4

$e% ti"e6 T i! 3a! i#itiated '& a eat t%eati#4 %elated defe5t i# t e 1te% !1%fa5e f t eta0e%ed ! a#96 T e 5%a59 4%e3 '& "etal fati41e a#d fi#all& failed 3 e# t%a$eli#4 $e% a

" de!t % ad !1%fa5e 0e%t1%'ati #6

Fi4 .6 @ie3 f a Failed Tie R d E#d B lt

it little e$ide#5e f a# e?t%e"e f %5e a00li5ati # at t e %i4 t %ea% !1!0e#!i #7 it

a00ea%ed 1#1!1al t at a ' lt 3 1ld f%a5t1%e f% " a# $e%l ad i# !15 a "a##e%6 T e ' lt 3a!

%e" $ed a#d te!ted6 T e e?te%i % !1%fa5e a%d#e!! 3a! f 1#d t $a%& 5 #!ide%a'l& al #4 t e

' lt le#4t 7 %e!1lti#4 i# a !t%e!! di!5 #ti#1it& at t e f%a5t1%e !1%fa5e6 T e # # 1#if %"it& f

a%d#e!! 551%%ed f% " i"0% 0e% eat t%eat"e#t f t e ' lt d1%i#4 "a#1fa5t1%e6

, 3' / F%'+ "

C %% !i # f "etal! 5a# 'e di!a!t% 1! t t %eaded fa!te#e%!6 S1%fa5e a#d 0itti#4

5 %% !i # atta59! t %eaded fa!te#e%! a! a %e!1lt f 5 #ta5t 3it " i!t1%e % t e% 5 %% di#4

"edia6 Si#5e ' lt! fte# 5a%%& i4 l ad!7 !t%e!! 5 %% !i # 5%a59i#4 (al! 5alled

e#$i% #"e#tall& a!!i!ted 5%a59i#4) i! a# t e% 5 %% !i # %elated fail1%e " de6 C %% !i #7

9


22/95

5 10led 3it f %5e! i# a ' lt7 te#d! t a55ele%ate 5%a59i#46 S15 fail1%e! a%e # %"all&

di!5 $e%ed d1%i#4 0e%i di5 i#!0e5ti #!6

1!5 G"/3"#3

Ge#!et al! 9# 3# a! 4e#e%at % !et i! a die!el f1el t&0e 4e#e%at % 1!ed t !100l&

e"e%4e#5& 0 3e%6 A die!el 4e#e%at % i! t e 5 "'i#ati # f a die!el e#4i#e 3it a# ele5t%i5

4e#e%at % ( fte# a# alte%#at %) t 4e#e%ate ele5t%i5al e#e%4&6 Die!el 4e#e%ati#4 !et! a%e 1!ed i#

0la5e! 3it 1t 5 ##e5ti # t t e 0 3e% 4%id7 a! e"e%4e#5& 0 3e% !100l& if t e 4%id fail!7 a!

3ell a! f % " %e 5 "0le? a00li5ati #! !15 a! 0ea9 l 00i#47 4%id !100 %t a#d e?0 %t t t e

0 3e% 4%id6 Si


23/95

Fi4 .6 Ma i#d%a Ge#!et

1!6 , "/# 9

T e 4e#!et "a#1fa5t1%e% a! !ta%ted 0% d15ti # f 4e#!et 3it t e i#te#ti # f

!tee%i#4 t ei% #e3 0% d15t (Ge#!et) i#t t e "a%9et6 T ei% ai" i! # t #l& t i#t% d15e t e 0% d15t '1t al! t 0e#et%ate dee0 i#t t e "a%9et6 T i! %e21i%e! a .** effi5ie#t7 3 %9i#47

d1%a'le7 e5 # "i5al a#d " !t i"0 %ta#tl& a fail!afe de!i4#6

I# %de% t 0% d15e a fail!afe de!i4#7 a !"all !e5ti # f t e de!i4# a#d a#al&!i! f t e

4e#!et7 i6e67 t e ' lted 8 i#t7 i! ta9e# 10 a#d 3 %9 i! d #e # it !15 t at it d e! # t 5 "e ff

% fail i# a#& 5i%51"!ta#5e6 Diffe%e#t a!!e"'lie! a%e a!!e"'led t #e a# t e% t f %" a

5 "0lete 4e#!et6 T e "ai# 5 "0 #e#t! 3 i5 5a1!e t e fail1%e f a ' lt a%e t e e#4i#e a#d

alte%#at % " 1#ti#4! a! t e& a%e t e "a8 % ea$& 0a%t! i# t e !t%15t1%e6 A0a%t f% " 'ei#4

11


24/95

ea$&7 t e& a%e t e ! 1%5e f $i'%ati #! i# t e e#ti%e a!!e"'l&6 T 1!7 if t e ' lt! 5 ##e5ti#4

t e e#4i#e/alte%#at % t t e 'a!e f%a"e a%e !afe7 t e# it i! e$ide#t all t e t e% ' lt! a%e !afe a!

"et%i5 ' lt! f !a"e "ate%ial i! 1!ed t % 14 1t6

T d t e a#al&!i! # t e ' lted 8 i#t7 t e e#ti%e 'a!e f%a"e i! fi%!t " deled7 a#d t e#

t e a'1t"e#t! a%e " deled 3 ile "ai#tai#i#4 t e 5 #e f 5 "0%e!!i # '& 1!i#4

HY=ERMESH6 C #ta5t! a%e t e# defi#ed i# %de% t 5 "0lete t e " deli#46 Afte%

5 "0leti#4 t e " deli#47 t e a#al&!i! i! 5a%%ied 1t i# ABA US ! ft3a%e6 T i! 3 %9 i! d #e

t 5 e59 if t e ' lted 8 i#t i! !afe 3it t e l ad a5ti#4 # it6

12


25/95

13


26/95

C a0te% -

Lite%at1%e Re$ie3


27/95

2! LITERATURE RE*IE

A# e?a"0le f ' lted 8 i#t i! a! !ee# i# t e fi41%e -6. 'el 36 T e ' lt i! 1!ed t fi?

t3 a'1t"e#t! (0late!) t 4et e%6

Fi4 -6. A T&0i5al B lted C ##e5ti #

A 3a! e% i! 1!ed 81!t 1#de% t e ' lt ead a#d a' $e a'1t"e#t . (! "eti"e!7 a 3a! e%

i! al! 0%e!e#t 81!t 'el 3 a'1t"e#t - a#d a' $e t e #1t) a#d #1t i! ti4 te#ed f% " 'el 36 T e

de!i4# f a ' lted 8 i#t7 li9e t e de!i4# f a#&t i#4 el!e7 i#$ l$e! detailed 5 #!ide%ati # f

f1#5ti #7 ! a0e!7 "ate%ial!7 di"e#!i #!7 3 %9i#4 l ad!7 3 %9i#4 e#$i% #"e#t7 et56

$%# H% "/3 $"/ A B +# I3 T':$#"/"

St%15t1%all&7 a ' lt !e%ie! #e f t3 01%0 !e!

• It 5a# a5t a! a 0i# t 9ee0 t3 % " %e 8 i#t "e"'e%! f% " !li00i#4 %elati$e t

ea5 t e%6

• It 5a# a5t a! a ea$& !0%i#4 t 5la"0 t3 % " %e 0ie5e! t 4et e%6

I# t e $a!t "a8 %it& f a00li5ati #!7 t e ' lt i! 1!ed a! a 5la"06 I# eit e% 5a!e7

3e$e%7 t e ' lt "1!t 'e ti4 te#ed 0% 0e%l& if it i! t 0e%f %" it! i#te#ded f1#5ti #6 B1t7 t e

"ai# 01%0 !e f t e ' lt i! t 5la"0 t3 % " %e t i#4! t 4et e%6

12


28/95

e# a ' lt i! ti4 te#ed 1!1all& '& t1%#i#4 t e #1t % t1%#i#4 t e ead f t e ' lt

t e ' lt i! !t%et5 ed '& a !"all a" 1#t6 If it i! # t !t%et5 ed7 it 3ill # t 0% $ide a#& 5la"0i#4

f %5e # t e 0a%t! 'ei#4 eld t 4et e%6 It "1!t 'e !t%et5 ed i# %de% t 'e effe5ti$e a! a 5la"06

Be5a1!e !t%et5 "ea#! !t%ai# 7 t1%#i#4 t e #1t i#t% d15e! te#!ile !t%e!! t t e fa!te#e%6 T i!

i#itial 5la"0i#4 f %5e a#d/ % t e te#!i # i# t e fa!te#e% i! 1!1all& 5alled =%el ad 6 e#

ti4 te#i#4 t e #1t % t1%#i#4 t e ead f t e ' lt i! !t 00ed7 ! "e f t e !t%e!! 3 i5 a$e

'ee# i#t% d15ed t t e fa!te#e% 3ill di!a00ea% (t e fa!te#e% %ela?e!)7 t a#9! t !15 t i#4! a!

t e l 5ali


29/95

!i"0le7 i#e?0e#!i$e7 a#d effe5ti$e 3a& t 5 #!i!te#tl& a#d a551%atel& ti4 te# a fa!te#e% d e!

# t e?i!t6 T e%e a%e a #1"'e% f te#!i #i#4 "et d! t at f1#5ti # 3ell e# 14 '1t t e& a%e

' t 5 "0li5ated a#d e?0e#!i$e6 I# " !t !it1ati #!7 le!! t a# 0e%fe5t t%aditi #al "et d! a%e

!1ffi5ie#t6

H 3e$e%7 51%%e#t t%e#d! a%e " $i#4 a3a& f% " t e 1!e f $e% de!i4#6 I#5%ea!i#4

de"a#d! # 5 !t7 !t%e#4t t 3ei4 t %ati !7 0% d15t !afet&7 0% d15t 0e%f %"a#5e7 a#d

e#$i% #"e#tal !afet& a$e 01t 0%e!!1%e # de!i4#e%!7 "a#1fa5t1%e%!7 a#d a!!e"'le%! t

i#5%ea!e de!i4# effi5ie#5&6 T i! t%e#d a! lead t t e i#$e#ti # f " %e 0ti #! i# 5 #t% lli#4

' lt 0%el ad6

I/-S" 8' " B"$%8' T$" J '/#

=%el adi#4 a fa!te#e% 0% 0e%l& i! a "a8 % 5 alle#4e7 '1t it ! # t all6 A! ! # a! t e

8 i#t i! 01t i#t 1!e7 it 3ill e#5 1#te% #e % " %e t&0e! f 3 %9i#4 l ad7 i#5l1di#4 !15

t i#4! a! te#!i # l ad!7 ! ea% l ad!7 0%&i#4 l ad!7 5&5li5 l ad!7 a#d l ad! 3 i5 a%e a

5 "'i#ati # f t e!e a#d t e% 0 !!i'ilitie!6 A#d t e!e e?te%#al l ad! add t % !1't%a5t f% "

t e i#itial te#!i # i# t e fa!te#e% i# 3a&! t at a%e fte# a%d t 1#de%!ta#d a#d al3a&! a%d t

0%edi5t6 It i! t # te t at #e f t e %ea! #! t e 8 i#t ! %ea5ti # t 3 %9i#4 l ad! i! a%d t

0%edi5t i! t e fa5t7 t at t e!e a%e # t a !&!te" f %i4id ' die!7 '1t7 i#!tead7 a !&!te" f ela!ti5!0%i#4!6 I# " !t 5a!e!7 e5 # "i5 5 #!t%ai#t! 3ill f %5e t e de!i4#e% t 5 0e 3it !15

1#5e%tai#tie! '& $e%de!i4#i#4 t e 8 i#t a#d/ % '& 'a!i#4 de!i4# de5i!i #! ! lel& # 41t feel

% 0a!t e?0e%ie#5e6 I# " %e i"0 %ta#t !it1ati #!7 0e% a0! 3 e%e 3ei4 t7 !i


30/95

Fi4 -6+ A Si"0le J i#t Dia4%a"

T e dia4%a" ! 3# a' $e 0%e!e#t! t e 3a& t at t e 'a!i5 8 i#t dia4%a" i!

5 #!t%15ted6 A! a #1t i! % tated # a ' lt ! !5%e3 t %ead a4ai#!t a 8 i#t7 t e ' lt i! e?te#ded6

Be5a1!e i#te%#al f %5e! 3it i# t e ' lt %e!i!t t i! e?te#!i #7 a te#!i # f %5e % ' lt 0%el ad i!

4e#e%ated6 T e %ea5ti # t t i! f %5e i! a 5la"0 f %5e t at i! t e 5a1!e f t e 8 i#t 'ei#4

5 "0%e!!ed6 T e f %5e e?te#!i # dia4%a" 0%e!e#ted a' $e ! 3! t e ' lt e?te#!i # a#d t e

8 i#t 5 "0%e!!i #6 T e !l 0e f t e li#e! %e0%e!e#t! t e !tiff#e!! f ea5 0a%t6 T e 5la"0ed

8 i#t 1!1all& 'ei#4 !tiffe% t a# t e ' lt6

Fi4 -6, J i#t Dia4%a" Afte% T e J i#t i! Cla"0ed B& A B lt

T e 'a!i5 8 i#t dia4%a" i! f %"ed '& " $i#4 t e 5 "0%e!!i # li#e f t e 8 i#t t t e

%i4 t6 A t%ia#4le i! f %"ed 'e5a1!e t e 5la"0ed f %5e te#di#4 t 5 "0%e!! t e 8 i#t i! e21al t

t e ' lt 0%el ad6 = !iti$e e?te#!i # i! t t e %i4 t !15 a! t at !1!tai#ed '& t e ' lt7 #e4ati$e

e?te#!i # (5 "0%e!!i #) i! t t e left a#d i! !1!tai#ed '& t e 8 i#t "ate%ial6

e# a# e?te%#al te#!ile f %5e i! a00lied t t e 8 i#t it a! t e effe5t f %ed15i#4 ! "e

f t e 5la"0 f %5e 5a1!ed '& t e ' lt ! 0%el ad a#d a00l&i#4 a# additi #al f %5e t t e ' lt

it!elf6 T i! i! ill1!t%ated i# t e 8 i#t dia4%a" ! 3# a' $e6 T e e?te%#al f %5e a5t! t % 14 t e 8 i#t "ate%ial a#d t e# !1'!e21e#tl& i#t t e ' lt6 At fi%!t !i4 t it "a& !ee" a 'it !t%a#4e t

15


31/95

0la5e t e a00lied f %5e i# t e 0 !iti # ! 3# i# t e dia4%a"6 H 3e$e%7 it ! 1ld 'e %eali


32/95

J '/# F%'+ " M "3

T e ' lt "a& fail d1%i#4 it! !e%$i5e6 T e %e!0 #!e f t e 8 i#t t !e%$i5e l ad! 3ill

5a1!e ! "e !0e5ifi5 t&0e! f 8 i#t fail1%e6 S15 fail1%e! "a& 'e 'e5a1!e f $i'%ati #

l !e#i#47 fati41e7 a#d lea9! f% " 4a!9eted 8 i#t!7 f % e?a"0le6 T 1#de%!ta#d t e 5a1!e! a#d

51%e! f % fail1%e7 t e%e a%e # " %e ea!& % fi#al a#!3e%! t t i! 0a%t f t e ' lti#4 e21ati #

t a# t e%e a%e t a!!e"'l&6 T e $a%ia'le! fa5ed a%e t #1"e% 1! t 5 #t% l7 % at lea!t t e&

a%e 3it t e i#f %"ati # 51%%e#tl& a$aila'le6 B lti#4 te5 # l 4& i! 81!t e"e%4i#4 ' lti#4 i!

!till " %e f a# e"0i%i5al a%t t a# a !5ie#5e at 0%e!e#t6 M !t f t e 0% 'le"! a%e ! l$ed '&

ed15ated t%ial a#d e%% %6 I# "a#& 5a!e!7 #l& a f1ll !5ale e?0e%i"e#t 3ill 4i$e t e i#f %"ati #

#eeded t ! l$e a 0% 'le"6 A#d " !t %e# 3#ed de!i4#e%! !a&7 If it ai# t '% 9e7 d # t fi? itP;

T at i!7 a de!i4# % !155e!!f1l a!!e"'l& 0% 5ed1%e i! #e$e% t 'e 5 a#4ed f % a t e %eti5all& 'ette% #e 1#le!! 0% 'le"! a%e 551%%i#4 % #eed t i"0% $e t e 0e%f %"a#5e f t e 0% d15t

% !&!te"6

2!1 A/%+


33/95

3 e%e7 9 i i! t e !tiff#e!! f t e i t la&e%6 T e ' lt !tiff#e!!7 9 ' 7 5a# 'e e!ti"ated i# te%"! f t e

5% !! !e5ti #al a%ea f t e ' lt7 A ' 7 Y 1#4Q! " d1l1! f % t e ' lt7 E ' 7 a#d t e le#4t f t e

' lt7 L ' 7 a!

k b = Ab Eb

Lb (-6-)

T e t tal !tiff#e!! f t e 8 i#t7 9 87 5a# 'e 5 "01ted ('& a!!1"i#4 t3 !0%i#4! i# 0a%allel) a!

k j= k b+ k m (-6+)

2!2 FEA B%3" E& ' ' %+ A % $"3

Fi#ite ele"e#t a#al&!i! i! t dete%"i#e t e 5la"0ed "ate%ial !tiff#e!! f % t3 0late!

"ade f t e !a"e "ate%ial6 It i! 'a!ed # a !ta#da%d !0%i#4 !tiff#e!! " del f % t e $e%all

8 i#t6 T e %e!1lt! f t i! 3 %9 0% d15e a 5la"0ed "ate%ial !tiff#e!! f % 5 ""e%5ial "etal! f

k m = 0.78952 E d b e0.62914 (dbl ) (-6,)

3 e%e7 E i! t e Y 1#4Q! " d1l1! f t e "ate%ial7 d ' i! t e dia"ete% f t e ' lt a#d l i! t e

t i59#e!! f t e 5la"0ed "ate%ial! (i6e67 t e t3 0late!)6

18


34/95

19


35/95

C a0te% +

Met d l 4&


36/95

! METHODOLOGY

!1 . # D"8"+ &"/# ,< +" N.I

S155e!!f1ll& la1#5 i#4 a #e3 0% d15t i#t t e "a%9et i#$ l$e! a #1"'e% f

5 alle#4i#4 a#d 5 "0le? ta!9!7 ea5 5%iti5all& li#9ed t t e #e 0%e5edi#4 it6 All t fte#

4%eat 0% d15t idea! fall fa% ! %t f e?0e5tati #! % fail alt 4et e% 'e5a1!e #e % " %e ta!9!

d e! # t %e5ei$e t e #e5e!!a%& le$el f atte#ti #6 T i! i! e!0e5iall& t%1e if t e 0% d15t 5 #5e0t

i! # t f1ll& $alidated d1%i#4 te!ti#4 % 3 %!e &et7 a $alidated 0% d15t a! # t 'ee# 0ti"i


37/95

I# t e fi%!t '1''le (!ta4e) defi#ed i# t e 5&5le7 36%6t t e a%ea f 5 #5e#t%ati #7 t e

Idea/C #5e0t1al de!i4# !ta4e i#5l1de! a d%aft de!i4# 5 $e%i#4 all t e feat1%e! de!i%ed i# t e

0% d15t7 i# 3 i5 t e l 5ati # f ' lt!7 t e !i


38/95

• Ba!e F%a"e

o Mai# F%a"e C Se5ti #

o C ##e5ti#4 Rail! Hat Se5ti #

• Ba!e F%a"e Mate%ial CRCA (5 ld % lled 5l !ed a##ealed) Steel

• Si


39/95

Fi4 +6+ C1""i#! Ja9! # Ge#!et ( * K@A) A#d E#4i#e A#d Alte%#at % M 1#ti#4!

• E#4i#e Ma9e C1""i#!

• Ba!e F%a"e

o Mai# F%a"e C Se5ti #o C ##e5ti#4 Rail! C Se5ti #

• Ba!e F%a"e Mate%ial CRCA (5 ld % lled 5l !ed a##ealed) Steel

• Si


40/95

Fi4 +6, Da"a? Ge#!et (,* K@A) A#d E#4i#e A#d Alte%#at % M 1#ti#4!

•

E#4i#e Ma9e Da"a?• Ba!e F%a"e

o Mai# F%a"e C Se5ti #o C ##e5ti#4 Rail! C Se5ti #

• Ba!e F%a"e Mate%ial Steel

Ma i#d%a Ge#!et

• E#4i#e Ma9e Ma i#d%a

• Alte%#at % C% "0t # G%ea$e!

• Ba!e F%a"eo Mai# F%a"e C Se5ti #o C ##e5ti#4 Rail! C Se5ti #

• Ba!e F%a"e Mate%ial CRCA (5 ld % lled 5l !ed a##ealed) Steel• Si


41/95

D"3':/= *%+' %#' /

T e l 5ati # f ' lt! i! "ai#l& ide#tified 3 e%e 5la"0i#4 i! #e5e!!a%&6 B1t 0%e5i!el&

l 5ati#4 f ' lt! i! dete%"i#ed '& f ll 3i#4 %1le f t 1"' a#d a fe3 !0e5ifi5ati #!6 = i#t!

'el 3 a%e t e 5 #diti #! t 'e 9e0t i# "i#d t fi#ali


42/95

De0e#di#4 # t e !i


43/95

Fi4 +6 St%e!! C #5e#t%ati # # @a%i 1! L 5ati # f B lt i# a J i#t

Fi41%e +6 ! 3! t e !t%e!!e! i# t %ee diffe%e#t #1t!6 O'$i 1!l&7 t i! !t%e!! 0i5t1%e i!

# t a# att%a5ti$e #e6 Si#5e " !t f t e l ad i! # t e fi%!t t %ead % ! 7 " !t f t e #1t i!# t

d i#4 it! ! a%e f t e 3 %96 T i! !it1ati # 5a# 'e i"0% $ed i# a #1"'e% f 3a&! ta0e%i#4

t e t %ead! % alte%i#4 t e 0it5 # eit e% #1t % ' lt t f %5e " %e 1#if %"it& i# l ad

di!t%i'1ti #7 f % e?a"0le6 =e% a0! t e " !t 0 01la% 3a& i! t 1!e a #1t t at i! 0a%tiall& i#

te#!i #6

Fi4 +6 St%e!! Le$el! i# T %ee Diffe%e#t N1t!

!2!2 T"/3'+" S# "33 A "%

Te#!ile !t%e#4t i! t e "e5 a#i5al 0% 0e%t& " !t 3idel& a!! 5iated 3it !ta#da%d

t %eaded fa!te#e%!6 Te#!ile !t%e#4t i! t e "a?i"1" te#!i # a00lied l ad t e fa!te#e% 5a#

26


44/95

!100 %t 0%i % t f%a5t1%e6 T e te#!ile f %5e %e21i%ed t &ield % '%ea9 t e ' lt % t e te#!ile

l ad a fa!te#e% 5a# 3it !ta#d i! dete%"i#ed '& t e f %"1la

F = σ As (+6.)

3 e%e7 F F %5e 3 i5 3ill fail t e ' lt

T e 1lti"ate te#!ile % &ield !t%e#4t f t e ' lt "ate%ial

AS Effe5ti$e St%e!! A%ea f t e t %ead!

F % t i! %elati #! i07 !i4#ifi5a#t 5 #!ide%ati # "1!t 'e 4i$e# t t e defi#iti # f t e

te#!ile !t%e!! a%ea7 AS6 e# a !ta#da%d t %eaded fa!te#e% fail! i# 01%e te#!i #7 it t&0i5all&

f%a5t1%e! t % 14 t e t %eaded 0 %ti # (a! t i! i! 5 a%a5te%i!ti5all& it! !"alle!t a#d t e%ef %e

3ea9e!t a%ea)6 F % t i! %ea! #7 t e te#!ile !t%e!! a%ea i! 5al51lated t % 14 a# e"0i%i5al

f %"1la i#$ l$i#4 t e # "i#al dia"ete% f t e fa!te#e% a#d t e t %ead 0it5 6

Fi4 +6 Te#!ile St%e!! St%ai# Dia4%a"

27


45/95

A! t e fa!te#e% a00% a5 e! t e "a?i"1" !t%e#4t f t e t %eaded 0 %ti #7 it 3ill

0e%"a#e#tl& def %"6 T a$ id t i! %i!97 " !t 5a%' # % all & !teel ' lt! a$e a defi#ed 0% f

l ad7 3 i5 %e0%e!e#t! t e 1!a'le !t%e#4t %a#4e f % t at 0a%ti51la% fa!te#e%6 B& defi#iti #7 t e

0% f l ad i! a# a00lied te#!ile l ad t at t e fa!te#e% "1!t !100 %t 3it 1t 0e%"a#e#t

def %"ati #6 I# t e% 3 %d!7 t e ' lt %et1%#! t it! %i4i#al ! a0e #5e t e l ad i! %e" $ed6

T e %elati #! i0 'et3ee# te#!i # a#d ' lt !t%et5 5a# 'e '!e%$ed # a Te#!ile St%e!! St%ai#

Dia4%a" i# fi41%e +6 6 If t e l ad i! %e" $ed a#d t e fa!te#e% i! !till 3it i# t e ela!ti5 %a#4e7

t e fa!te#e% 3ill al3a&! %et1%# t it! %i4i#al ! a0e6 H 3e$e%7 if t e l ad a00lied 5a1!e! t e

fa!te#e% t e?5eed it! &ield 0 i#t7 it e#te%! t e 0la!ti5 %a#4e6 At t i! 0 i#t7 t e !teel i! #

l #4e% a'le t %et1%# t it! %i4i#al ! a0e if t e l ad i! %e" $ed6 T e &ield !t%e#4t i! t e

0 i#t at 3 i5 a !0e5ified a" 1#t f 0e%"a#e#t def %"ati # 551%!6 If t e l ad i!

5 #ti#1 1!l& a00lied f1%t e%7 a 0 i#t f "a?i"1" !t%e!! 9# 3# a! t e 1lti"ate te#!ile

!t%e#4t i! %ea5 ed6 =a!t t i! 0 i#t7 t e fa!te#e% 5 #ti#1e! t #e59 d 3# a#d el #4ate f1%t e%

3it a %ed15ti # i# !t%e!!6 Additi #al !t%et5 i#4 3ill 1lti"atel& 5a1!e t e fa!te#e% t '%ea9 at

t e te#!ile 0 i#t6

! M%#" '%+3

Mate%ial Sele5ti # f t e B lt i! a! 5%15ial a! de!i4#i#4 t e ' lt 8 i#t6 I"0% 0e%

!ele5ti # f t e ' lt "ate%ial 3ill d%ai# all t e eff %t! f t e ' lt de!i4#i#46 T e%ef %e7

"ate%ial !ele5ti # a! t 'e d #e 9ee0i#4 i# "i#d t e 0% 0e%tie! 3 i5 affe5t t e 5la"0i#4

f %5e

• Ma4#it1de f Cla"0i#4 F %5e (De0e#d! # t e 'a!i5 te#!ile !t%e#4t f t e "ate%ial)• Sta'ilit& f Cla"0i#4 F %5e (Ca# 'e affe5ted d1e t "ate%ial 0% 0e%tie! 3 i5 5a#

effe5t li9e te"0e%at1%e7 5 %% !i #7 !t%e#4t 7 et56)• T e%"al E?0a#!i # % C #t%a5ti #• C %% !i #• Fati41e R10t1%e• L !! f St%e#4t 3it Te"0e%at1%e• L !! f 3it Cla"0i#4 F %5e Te"0e%at1%e• Ela!ti5 Stiff#e!! f t e =a%t!• C a#4e i# Stiff#e!! 3it Te"0e%at1%e• B%ittle F%a5t1%e

S"+" #' / A '%#" S#%/ % >

28


46/95

T e 01%0 !e f a fa!te#e% !ta#da%d i! t defi#e a 4% 10 f "ate%ial! a#d/ % fa!te#e%

5 #fi41%ati #! 3 i5 a%e a00% 0%iate f % t e t&0i5al #eed! f a 0a%ti51la% i#d1!t%& % a

0a%ti51la% 5la!! f a00li5ati #!6 T e !ta#da%d t e# "a9e! it 1##e5e!!a%& f % ea5 e#4i#ee% t

'e a "etall1%4i!t 3 e# t%&i#4 t dete%"i#e 3 at 3 1ld 'e a00% 0%iate i# i! a00li5ati #6 T i!

!a$e! a 4%eat deal f ti"e a#d " #e&6

T e%e a%e t3 %eadil& a$aila'le !et! t at a%e 3idel& 1!ed '& "i!5ella#e 1! i#d1!t%ie!

a#d de!i4#e%!6 T e " !t 5 "" #l& 1!ed ' lti#4 !ta#da%d7 i! SAEQ! +,- 7 3 i5 defi#e!

a1t " ti$e G%ade! I t % 14 6 B lt! f t e!e "ate%ial! a%e "ade i# la%4e 21a#titie! a#d a%e

t e%ef %e %elati$el& i#e?0e#!i$e a#d a%e %eadil& a$aila'le6 T e& %e 3idel& 1!ed f % !"all a#d

"edi1" !i


47/95

f %5e7 it 3ill el0 i# a#al&


48/95

E t e " d1l1! f ela!ti5it& (0!i7 G=a)

F t e a00lied te#!ile f %5e (l'67 N)

Si#5e t e $a%i 1! !e5ti #! a%e 5 ##e5ted i# !e%ie!7 t e& ea5 !ee t e !a"e f %5e7 ! 3e 5a#

5 "'i#e t e t3 e21ati #! a' $e a#d 3%ite7

∆ LC

= F ( L 1 E A 1 + L 2 E A 2 + L3 E A 3 )(+6,)

N 37 t e !0%i#4 5 #!ta#t f a ' d& i! defi#ed a!

K = F ∆ L (+6 )

3 e%e7 K t e !0%i#4 5 #!ta#t % !tiff#e!! (l'/i#67 N/"")

T e !0%i#4 5 #!ta#t f a 4% 10 f ' die!7 5 ##e5ted i# !e%ie!7 i!

1

K T =

1

K 1+

1

K 2+

1

K 3

(+6 )

3 e%e7 K T t e 5 "'i#ed !0%i#4 5 #!ta#t f t e 4% 10 (l'/i#67 N/"")

K . 7 K - 7 et56 !0%i#4 5 #!ta#t! f i#di$id1al "e"'e%! f t e 4% 10 (l'/i#67 N/"")

N 37 t e e21ati # f % t e !0%i#4 5 #!ta#t f a ' d& 'e %e3%itte# a!

∆ L= F K

(+6 )

C "0a%i#4 t e e21ati # f % t e !0%i#4 5 #!ta#t f % a 4% 10 f ' die! t t e e21ati # f %

!t%et5 % 5 a#4e i# le#4t f a 4% 10 f ' die!7 3e 4et7

1

K T =

L1 E A1

+ L2

E A2+

L3 E A3

(+6 )

31


49/95

C a#4e i# Le#4t f t e B lt Effe5ti$e Le#4t

∆ LC

= F P( L be EA B + L se EA S) (+6 )

S#' /"33 B +#-N #- %3$" S


50/95

AC 5% !! !e5ti #al a%ea f t e e21i$ale#t 5&li#de% 1!ed t %e0%e!e#t t e 8 i#t i#

!tiff#e!! 5al51lati #! (i#6 - 7 ""-)

T t tal t i59#e!! f 8 i#t % 4%i0 le#4t (i#67 "")

!5 T':$#"/'/: T$" J '/#

T e ti4 te#i#4 f t e 8 i#t "ea#! e!ta'li! i#4 t e e?a5t 5la"0i#4 f %5e %e21i%ed f %

t e 8 i#t6 T e 5la"0i#4 f %5e i! 5%eated 3 e# t e ' lt! a%e ti4 te#ed d1%i#4 a!!e"'l&6 e#

t e ' lt! a%e 0%el aded7 te#!i # i! 5%eated i# t e"7 '& t1%#i#4 t e #1t % ' lt 3 ile ldi#4 t e

t e%6 D1%i#4 i#itial a!!e"'l& f a# i#di$id1al ' lt t e%e ! a #e t #e %elati #! i0 'et3ee#

t e te#!i # i# a ' lt a#d itQ! 0%el ad6 T e te#!ile l ad i# a ' lt 3ill 5 a#4e a! t e t e% ' lt!

a%e ti4 te#ed a#d/ % t e 8 i#t i! 01t i# !e%$i5e7 ! t e 0%el ad i! a# i#itial a#d ! %t li$ed

affai%6 Ne$e%t ele!!7 it ! e?t%e"el& i"0 %ta#t6

T %eaded fa!te#e%! 5a# 5la"0 "ate%ial! t 4et e% #l& 3 e# t e& a%e ldi#4 3it t e

0% 0e% a" 1#t f te#!i #6 F % t i! t a00e# t e& "1!t 'e 0% 0e%l& ti4 te#ed6 T t i! da& a

!i"0le7 i#e?0e#!i$e7 a#d effe5ti$e 3a& t 5 #!i!te#tl& a#d a551%atel& ti4 te# a fa!te#e% d e!

# t e?i!t6 T e%e a%e a #1"'e% f te#!i #i#4 "et d! t at f1#5ti # 3ell e# 14 '1t t e& a%e

' t 5 "0li5ated a#d e?0e#!i$e6 I# " !t !it1ati #!7 le!! t a# 0e%fe5t t%aditi #al "et d! a%e!1ffi5ie#t6

T ; " , /# +

T %21e i! #e f t e " !t 5 "" # "et d! f i#!talli#4 fa!te#e%!6 Ofte# a t %21e

$al1e i! !0e5ified f % a 4i$e# a00li5ati # a#d 3it t e 1!e f a 5ali'%ated t %21e 3%e#5 7 t i!

t %21e $al1e 5a# 'e 'tai#ed6 H 3e$e%7 t i! %eadi#4 d e! # t i#di5ate t e ' lt te#!i #di%e5tl&6 Rat e% t e t %21e %eadi#4 i! #l& a# i#di%e5t i#di5ati # f t e de!i%ed te#!i #6 D1%i#4

ti4 te#i#4 % 14 l& * f i#01t e#e%4& i! l !t $e%5 "i#4 t e "ati#4 f%i5ti # 1#de% t e ead7

#1t7 a#d "ati#4 t %ead!6 O#l& .* f i#01t e#e%4& i! 5 #$e%ted i#t ' lt !t%et5 6 B1t t i! i!

a# $e%!i"0lifi5ati # f 3 at "a& a5t1all& a00e#7 !i#5e # 5 #!ide%ati # i! 4i$e# t t e

$a%i 1! f %"! f eat a#d !t%ai# e#e%4& i#t% d15ed i#t t e !&!te"6

33


51/95

I# " !t !it1ati #! t e%e i! a %elati$el& !i"0le %elati #! i0 'et3ee# t e t %21e a00lied

t t e ' lt % #1t a#d t e te#!i # 5%eated i# it6 U!1all& t i! %elati #! i0 i! li#ea%6 F % !15

5a!e!7 t e e21ati # i! a00li5a'le

Torque = K x d x F (+6.-)

3 e%e7 d t e # "i#al dia"ete%

F i! t e 5la"0 l ad

K N1t Fa5t %

T e K7 % #1t fa5t %7 5a# 'e t 14 t f a! a#&t i#4 t at i#5%ea!e! % de5%ea!e! t e

f%i5ti # 3it i# t e t %ead! f t e #1t6 T i! i! a 5 "'i#ati # f t %ee !1' fa5t %!

K . 7 a 4e "et%i5 fa5t % t e ! a0e f t e t %ead!6 @a%iati # i# t e ! a0e f t e t %ead

"a& 5a1!e f%i5ti # i# i#5%ea!e % de5%ea!e6

K - 7 a t %ead f%i5ti # %elated fa5t % t e f%i5ti # 'et3ee# t e t %ead! f t e ' lt a#d t e

t %ead! f t e #1t6

K +7 a# 1#de% ead f%i5ti # %elated fa5t % t e f%i5ti # f t e #1t a4ai#!t t e !1%fa5e it

% tate! #6

H 3e$e%7 t e%e a%e 01'li! ed ta'le! f % K7 f% " 3 e%e t i! #1t fa5t % 5a# 'e 'tai#ed6

B +# , / '#' / N # 0lated7 'la59 fi#i! (d%&) *6-* *6+*

i#5 0lated *6. *6--L1'%i5ated *6.- *6.

Cad"i1" 0lated *6.. *6.

Ta'le +6- N1t Fa5t %!

A! a 4% 10 f fa!te#e%! i! ti4 te#ed7 t !e ti4 te#ed fi%!t 3ill te#d t %ela? !li4 tl& a!

!1'!e21e#t fa!te#e%! a%e ti4 te#ed6 T i! i! d1e t t e 5%ee0 a#d fl 3 f ea$il& l aded 5 #ta5t

!1%fa5e! a#d t e %ela?ati # 'et3ee# 4% 10! f ' lt! a! t e& a%e i#di$id1all& ti4 te#ed6 T e

34


52/95

fi%!t ' lt! ti4 te#ed 0a%tiall& 01ll t e 8 i#t t 4et e%6 A! t e %e!t f t e ' lt! a%e ti4 te#ed7 t e

8 i#t i! f1%t e% 5 "0%e!!ed7 a#d t e 0%e$i 1!l& ti4 te#ed ' lt! %ela? a#d l !e ! "e f t ei%

0%el ad6 I# ! "e 5a!e!7 t i! 5a# $i%t1all& eli"i#ate ' lt te#!i #6 If ' lt te#!i # i! de!i%ed 3it

a i4 de4%ee f a551%a5&7 t e t %21e 3%e#5 i! # t t e a#!3e%6

M"# '

B +#

S#%/ % H':$ LT"/3'+"

S# "33

A "%

(&& 2)

T ; "

(N-M)

F%3#"/"

,+%&

L % =. "+ %

(9N)

T ; "

(N-M)

F%3#"/"

,+%&

L % =. "+ %

(9N)

T ; "

(N-M)

F%3#"/"

,+%&

L % =. "+ %

(9N)M ?. .-V+ .+ .+V+ ., V. -*6.

M ?.6- - V -- +*V -+ . V+ .- + 6

M.*?.6 V.* +, *V.- + +*V .M.-?.6 .**V-* - .* V-* *V.* - ,6+M.,?- . *V+* . . V+* *V. + ..M. ?- -,*V,* , - *V,* .* .- V-* , .

M-*?-6 , *V * .,, +*V * . - *V,* -,M-,?+ **V.** -* **V.** -+, ,- V * ... + +

M+*?+6 . **V-** +++ . **V-** + *V.** . .M+ ?, - **V+** , +.**V+ * + . **V-** - * .

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e21ati # +6.-6 B1t t e a" 1#t f t %21e #eed# t 'e 5al51lated all $e% a4ai# 'e5a1!e t e%e a%e

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t e a" 1#t f t %21e %e21i%ed f % l 3/!ta#da%d/ i4 te#!i #i#4 f ' lt!6

T ; " %/ T / , /# +

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< #e!6

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!1%fa5e! a%e d%a3# i#t ali4#"e#t % a :!#14; 5 #diti #6

35


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+6 T e ela!ti5 5la"0i#4 %a#4e < #e 'ei#4! 3it t e a00li5ati # f t e a#4le 5 #t% lled

ti4 te#i#46 T % 14 t i! %e4i # t e !l 0e f t e t %21e a#4le 51%$e i! 5 #!ta#t6,6 T e 0 !t &ield < #e i! 3 e%e a# i#fle5ti # 0 i#t (0e%"a#e#t def %"ati #) 'e4i#!6

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A! a %e!1lt7 01%e t1%# 5 #t% l a! a i4 0 te#tial f % i#a551%a5&6 B1t t e fa5t %e"ai#! t at t e

0%el ad a00lied t a 0%e$i 1!l& !#144ed ' lt i#di5ate! ' lt 0%el ad %e4a%dle!! f f%i5ti #6

T 1!7 t e 5 "'i#ati # f t %21e a#d t1%# i! " %e a551%ate t a# eit e% !&!te" al #e6 A

%e0%e!e#tati # f t e t %21e t1%# 0% 5ed1%e i! a! ! 3# i# fi41%e +6 6

Fi4 +6 T %21e a#d T1%# =% 5ed1%e

T %21e i! 1!ed t dete%"i#e t e i#itial 0%el ad de$el 0ed i# a fa!te#e% d1%i#4 t e

!#144i#4 0e%ati #6 Re4a%dle!! f t e e?te%#al fa5t %! t at 5a# i#fl1e#5e t %21e7 t i! !e%$e! a!

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te#!i # f a 0%e$i 1!l& :!#144ed; ' lt6 O#5e t e !la59 a! 'ee# ta9e# 1t f t e a!!e"'l&

t % 14 t e 1!e f t %21e7 it i! ea!& t dete%"i#e t e a" 1#t f t1%# #eeded t %ea5 t e

0% 0e% 0%el ad f % t e ' lt6

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t e 8 i#t a#d t e fa!te#e%6 T i! i#5%ea!e! t e 5 !t f t e "et d6 T e "et d i! al! !i"ila% t

t e t %21e "et d i# t at it a! # 3a& t a55 1#t f % 0 e# "e#a li9e 5%ee0 %ela?ati # a#d

ti4 te#i#4 !e21e#5e6 A551%a5& i! !till affe5ted '& $a%ia'le! !15 a! f%i5ti # a#d !tiff#e!!

%ati !6

S# "# $ , /# +

36


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55/95


56/95

3a! e%! 5a# 'e 1!ed !i#41la%l& % !ta59ed i# a "ea#! t " dif& t e a" 1#t f defle5ti #6

Sta59i#4 i# t e !a"e di%e5ti # 3ill add t e !0%i#4 5 #!ta#t i# 0a%allel7 3 i5 3ill 5%eate a

!tiffe% 8 i#t6 Sta59i#4 i# a# alte%#ati#4 di%e5ti # 3 1ld 'e e21i$ale#t t addi#4 !0%i#4! i#

!e%ie!7 3 i5 3 1ld %e!1lt i# 4%eate% defle5ti #6 T&0i5al Belle$ille 3a! e%! a%e ! 3# i#

fi41%e +6..6

Fi4 +6.. Belle$ille a! e%!

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5 lla% i! t %eaded d 3# #t t e e?0 !ed !e5ti # f t %ead a' $e t e #1t6 H&d%a1li5 0%e!!1%e

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ti"e %e21i%ed f % t e ! 1#d t e5 ff t e e#d a#d %et1%# t t e t%a#!d15e%6 e# a ' lt i!

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"ea!1%e t e 5 a#4e i# t%a#!"ittal ti"e t dete%"i#e ' lt te#!i #6 T i! e21i0"e#t a! 'ee#

39


57/95

a$aila'le f % "a#& &ea%!7 '1t d1e t t e 5 !t a#d 21a#tit& f 5 "0 #e#t! #eeded7 i! 1!ed i#

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T':$#"/'/: S"; "/ "

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effe5t f ti4 te#i#4 #e ' lt i# t e 4% 10 a! a# effe5t # t e 0%el ad i# t e% 0%e$i 1!l&

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I# t e 51%%e#t 4e#!et de!i4#7 f % e!ta'li! i#4 t e 8 i#t7 t e St%et5 C #t% l fit! t e

0i5t1%e 0e%fe5tl& a! !t%et5 5 #t% l 4i$e! t e " !t 0ti"1" 0%el ad a#d t e%e i! e# 14

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t t e l ad! e#5 1#te%ed i# t e a1t " ti$e % ae% !0a5e i#d1!t%&6 T e e#4i#e $i'%ati #!

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L % 3

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f %5e 5la"0i#4 t e t3 0a%t! t 4et e%7 a#d t t e 5 effi5ie#t f f%i5ti # at t e i#te%fa5e6 T e

t tal f%i5ti # f %5e de$el 0ed i# t e 8 i#t i! 5alled t e !li0 %e!i!ta#5e (R S) f t e 8 i#t6 T e

e21ati # f % !li0 %e!i!ta#5e t e%ef %e i!

RS = S F P N!

(+6.,)

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WS !li0 5 effi5ie#t f t e 8 i#t

F= 0%el ad 0e% ' lt (l'7 N)

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N #1"'e% f ' lt! ldi#4 t e 8 i#t

M #1"'e% f !li0 !1%fa5e!

e# t e e?te%#al l ad! %ai!e i4 e# 14 t !li0 a f%i5ti # t&0e 8 i#t7 t e 8 i#t 0late!

3ill " $e $e% ea5 t e% 1#til 0%e$e#ted f% " f1%t e% " ti # '& t e ' lt!6 T i! 8 i#t i! # 3

5 #!ide%ed t 'e i# 'ea%i#46 T e 4e#e%al !t%e#4t f !15 a 8 i#t 5a# 'e % 14 l& e!ti"ated a!

f ll 3!

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= #1"'e% f ! ea% 0la#e!

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!7 J '/# F%'+ "

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f %5e 3ill 0% 'a'l& 'e i#!1ffi5ie#t 'e5a1!e f defi5ie#5ie! i# t e a!!e"'l& 0% 5e!!6 T e

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M" $%/' %+ F%'+ " T$" B +#3

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'%ea9 f % a $a%iet& f %ea! #!6

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Me5 a#i5al fail1%e d1%i#4 a!!e"'l& (t e "e5 a#i5 01lled t a%d # t e 3%e#5 )6Me5 a#i5al fail1%e at ele$ated te"0e%at1%e! (' lt !t%e#4t d% 00ed a! te"0e%at1%e

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l ad! i! d #e7 t e ' lt! ! 1ld # t '%ea9 'e5a1!e f "e5 a#i5al fail1%e6

L 3" B +#3 B +#3 T T':$#

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fail1%e 5a# 'e a$ ided6

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0la#e f t e ' lt t %ead! 01! i#4 t e i#5li#ed 0la#e f t e #1t t %ead! 1t f t e 3a&6

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B& 1!i#4 #e f t e 'el 3 "et d!7 $i'%ati # l !e#i#4 5a# 'e a$ ided

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F%#': " F%'+ "

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t i! data7 it i! a00a%e#t t at t e e#d1%a#5e li"it f " !t ' lt! i! !i4#ifi5a#tl& le!! t a# t e

e#d1%a#5e li"it f t e "ate%ial!6 Refe%%i#4 t i! data "i4 t el0 i# a$ idi#4 fati41e fail1%e6

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C a0te% ,

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4! ,OM.UTATIONAL STUDY

4!1 I/# #' / T , & #" A' " D"3':/ (,AD)

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a!!i!t 3it t e de!i4# f "a#1fa5t1%ed 0% d15t!7 t e '1ilt e#$i% #"e#t7 % fi5titi 1!

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64/95

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f%a"e!7 3 e%e ! a0e! 3e%e %e0%e!e#ted ! lel& '& t ei% $e%ti5e! a#d ed4e!6 ile

5 "01tati #all& !i"0le7 t e te5 #i21e 5 1ld # t e?0%e!! 5 "0le? !1%fa5e 51%$at1%e!7

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e?a5t 4e "et%& t da&6

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%e!0 #!e t t i! 0% 'le"7 CAD !&!te"! !ta%ted t a$e a % le i# a#al&


65/95

o it t e '% ade!t !et f di%e5t CAD a#d CAE i#te%fa5e! a#d t e a'ilit& t

defi#e 51!t " i#te4%ati #!7 H&0e%Me! 3 %9! !ea"le!!l& 3it i# a#&

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5 %0 %ati # "i#i"i


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o Tet%a Me! i#4o CFD Me! i#4

• Me! M %0 i#4o H&0e%M %0 i! 0 3e%f1l ! l1ti # f % i#te%a5ti$el& a#d 0a%a"et%i5all&

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%a0id ! a0e $a%iati #! # t e fi#ite ele"e#t "e! 3it 1t !a5%ifi5i#4 "e!

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FE " deli#4 f t e 4e#!et 'a!e f%a"e i! d #e 1!i#4 t e ! ft3a%e H&0e%Me! 6

Me! i#4 i! t e 5%eati # f "a#& #1"'e%! f ele"e#t! f % t e a#al&!i! 01%0 !e6 Me! i#4 i! f

t3 t&0e! ! lid a#d ! ell6 S lid "e! i#4 i! 5 #!ide%ed f % t e 5 "0 #e#t! % 0a%t! 3 !e

t i59#e!! i! " %e6 A#d S ell "e! i#4 i! 1!ed f % t e 5 "0 #e#t! 3 !e t i59#e!! i! le!!6

S lid "e! i#4 i! +D "e! i#4 a#d S ell "e! i#4 i! -D t&0e6 T e FE " deli#4 f 'a!e f%a"e

i! d #e 1!i#4 S ell t&0e f "e! i#46 T e "e! i#4 i! d #e 9ee0i#4 i# "i#d t e f ll 3i#44e#e%al %1le! f "e! i#4

R +"3 M"3$'/:

S "e %1le! f t 1"' 3 e# "e! i#4

• U!e a %elati$el& fi#e (5 a%!e) di!5%eti


68/95

Me! i#4 i! d #e # all 5 "0 #e#t! f 'a!e f%a"e6 Diffe%e#t 5 l %! a%e a!!i4#ed t

diffe%e#t 5 "0 #e#t!6 T e " !t i"0 %ta#t t i#4 i# t e "e! i#4 f % a#al&!i! i! t e

5 ##e5ti$it& f t e ele"e#t!6 1alit& 5%ite%ia f t e "e! i#4 al! #eed! t 'e 5 e59ed 'ef %e

4 i#4 f % a#al&!i! a! t e 5 "0 #e#t "a& fail if it d e!# t "eet t e %e21i%ed 21alit&6 T e

21alit& 5%ite%ia i#5l1de! Aspect Ratio, Warpage, Skew, Element Size, Connectivity between

elements, Free Edges, Ma and Min angles in !"ad and #ria Elements, $ength 7 et56

T e 21alit& 5%ite%i # t at 3a! 5 #!ide%ed f % t e FE " deli#4 f t e 4e#!et 'a!e f%a"e i!

• a!0e5t %ati X

• 3a%0a4e *

• !9e3 *

• 8a5 'ia# *6

• "a? 21ad a#4le .+

• "i# 21ad a#4le ,

•

"a? t%ia a#4le .-*

• "i# t%ia a#4le +*

48


69/95

Fi4 ,6. 1alit& C%ite%ia f 1ad A#d T%ia Ele"e#t!

T e Ba!e f%a"e Ge "et%& i! i"0 %ted t H&0e%"e! a#d Mid!1%fa5e f t e %e21i%ed

5 "0 #e#t! a%e e?t%a5ted6 T e FE " del i! '1ilt 1!i#4 t i! Mid!1%fa5e6 T e " del i! '1ilt

1!i#4 T%ia#41la% > Re5ta#41la% (=la#e ele"e#t!)6 T e 5 ##e5ti #! 'et3ee# ' lted

5 "0 #e#t! a0a%t f% " e#4i#e a#d alte%#at % " 1#ti#4!7 a%e " deled 1!i#4 %i4id ele"e#t!6T i59#e!! i! 5 #!ide%ed a#d a!!i4#ed a! 0% 0e%t& t t e 5 "0 #e#t6

T e ' lt!7 3a! e% a#d #1t7 i#!tead7 a%e " deled 1!i#4 ! lid "e! i#46 ile " deli#4

t e ' lt7 t e ele"e#t! #ea% t e !ta%t f t e ! a#97 !ta%ti#4 f t %ead! a#d t %ead e#4a4e"e#t

%e4i #! a$e t 'e "e! ed fi#el&6 T e "e! ed ' lt7 #1t a#d 3a! e% a%e ! 3# i# fi41%e ,6+6

B1t #e f t e a'1t"e#t! i! i# ! ell "e! 6 S t e a%ea f fa&i#4 !1%fa5e! i! %e" $ed f% "

! ell "e! a#d ! lid "e! i! d #e 3 ile "ai#tai#i#4 t e 5 #e f 5 "0%e!!i # # ' t t e

a'1t"e#t! a! ! 3# i# fi41%e ,6,6

49


70/95


71/95

Fi4 ,6+ M deled N1t7 B lt a#d a! e%

Fi4 ,6, C #e f C "0%e!!i # # B t A'1t"e#t!

51


72/95

Fi4 ,6 E"'ed"e#t f S lid a#d S ell Ele"e#t!

T e #e?t !te0 afte% "e! i#4 i! 5%eati # f 5 #ta5t!6 C #ta5t! a%e defi#ed (fi41%e ,6 )

1!i#4 t e Ma!te% a#d Sla$e 5 #5e0t6 Ge#e%al 41ideli#e! f % defi#i#4 a Ma!te% a#d a Sla$e

a$e t 'e 9e0t i# "i#d

• Ma!te% i! defi#ed f % a !tiffe% 0a%t a#d Sla$e f % t e t e%6

• If ' t a%e f !a"e !tiff#e!!7 Ma!te% i! defi#ed f % t e #e 3 i5 i! " %e %i4idl& eld7

i6e67 3 i5 a! " %e !tiff#e!! i# t e te%"! f 4e "et%&6

• Ma!te% i! defi#ed 3 i5 a! a 5 a%!e% "e! 6

• Sla$e 5a## t 0e#et%ate i#t t e Ma!te%6

• Ma!te% i! defi#ed f % la%4e% fa&i#4 !1%fa5e6

52


73/95

Fi4 ,6 C #ta5t!

A33 & #' /

T 1#de%!ta#d a#d 'tai# t e !t%e!! 'e a$i % i# a 'a!e f%a"e7 ! "e a!!1"0ti #! a#d

a00% ?i"ati #! 3e%e %e21i%ed6 He%e a#al&!i! 3a! 1#de%ta9e# 'a!ed # t e a!!1"0ti # t at

t e l ad a5ti#4 # t e 'a!e f%a"e i! 1#if %"l& di!t%i'1ted t % 14 1t t e 'a!e f%a"e f

4e#!et6 T e 3ei4 t! a5ti#4 # t e 'a!e f%a"e a%e t at f t e 5a# 0& ( 1te% !t%15t1%e)7 t e

3ei4 t! f e#4i#e a#d %adiat % 5 "'i#ed7 3ei4 t f t e alte%#at % a#d t e 3ei4 t f t e die!el

f1el ta#9 a!!1"i#4 it t 'e 5 "0letel& filled 3it t e f1el6 F % t e 1#if %" di!t%i'1ti#4 f t e

l ad # t e 'a!e f%a"e7 %i4id! a%e 5%eated # 0 i#t! f i#te%!e5ti # 3 e%e t e 'a!e f%a"e i!

5 ##e5ted % ' lted t t e 5a# 0&6

, "%#' / R':' 3

53


74/95

A %i4id ele"e#t i! a# ele"e#t 5%eated i# !0a5e 'et3ee# t3 # de! f a " del 3 e%e a

%i4id 5 ##e5ti # i! de!i%ed6 RBE3 i! t e 1!ed i# t i! 5a!e t a!!i4# t e "a!!e!6 RBE3 ! a%e

i#te%0 lati # 5 #!t%ai#t ele"e#t!7 3 e%e t e " ti # f a de0e#de#t # de i! defi#ed a! t e

3ei4 ted a$e%a4e f t e " ti #! f a 4% 10 f i#de0e#de#t # de!6

Fi4 ,6 C%eati # f Ri4id

I# t e #e?t !te07 t e effe5t f F1el ta#97 Alte%#at %7 E#4i#e7 Radiat %7 Ca# 0& l ad! i!

%eali


75/95

Fi4 ,6 =%ete#!i # a#d Ma!! A00li5ati # # Ba!e F%a"e

B / % < , / '#' /3

T e ' 1#da%& 5 #diti #! "1!t 'e defi#ed 'ef %e 4 i#4 i#t a#al&!i!6 T e!e i#5l1de

t e l ad! a00lied a#d t e di!0la5e"e#t 5 #!t%ai#t!6 I# t e %&7 all %ea5ti # f %5e! i# t e " del

! 1ld 'e i# e21ili'%i1"6 H 3e$e%7 t i! i! fte# # t t e 5a!e a#d t e " del 3 1ld 'e

di!0la5ed6 T 1! 5 #!t%ai#t! a%e %e21i%ed t a#5 % t e " del i# !0a5e6 T e ' 1#da%&

5 #diti # i! t e a00li5ati # f a f %5e a#d/ % 5 #!t%ai#t6 I# H&0e%Me! 7 ' 1#da%& 5 #diti #!

a%e !t %ed 3it i# 3 at a%e 5alled l ad 5 lle5t %!6

1ite fte# (e!0e5iall& at t e 'e4i##i#4) a l ad 5 lle5t % i! #eeded f % t e 5 #!t%ai#t!(al! 5alled S=C Si#4le = i#t C #!t%ai#t!) a#d a !e5 #d #e i! #eeded f % t e f %5e! a#d/ %

0%e!!1%e!6 A#& 5 #!t%ai#t 5a# 'e 0la5ed (e646 # de! 5 #!t%ai#t) 3it %e!0e5t t d f.7 % # de!

3it 5 #!t%ai#t! d f.-+7 et56 i# a !i#4le l ad 5 lle5t %6 T e !a"e %1le a00lie! f %

f %5e!/0%e!!1%e!6 T e& a%e !t %ed 3it i# a !i#4le l ad 5 lle5t % %e4a%dle!! f t ei% %ie#tati #

a#d "a4#it1de6 Di!t%i'1ted l ad! 5a# 'e a00lied '& "ea#! f a# e21ati #6 I# t e di!0la&ed

e?a"0le7 t e "a4#it1de f t e a00lied f %5e! $a%ie! 3it %e!0e5t t t e # dal & 5 %di#ate6

55


76/95

Fi4 ,6 =% $idi#4 B 1#da%& C #diti #!

A +


77/95

Fi4 ,6.* =% $idi#4 Di!t%i'1ted L ad!

Di!t%i'1ted l ad! ($a%&i#4 3it %e!0e5t! t t e 5 %di#ate! f t e # de! % ele"e#t!)

5a# 'e a00lied '& "ea#! f a# e21ati #6 I# t e di!0la&ed fi41%e7 t e "a4#it1de f t e a00lied

f %5e! $a%ie! 3it %e!0e5t t t e # dal & 5 %di#ate6

T e B 1#da%& 5 #diti #! a%e 5 #!ide%ed !15 t at it 3ill %e!e"'le t e 0%a5ti5al

5 #diti #6 I# a5t1al t e Ba!e f%a"e i! %e!ted # t e C #5%ete G% 1#d6 Ba!e f%a"e i!

5 #!t%ai#ed i# !1ffi5ie#t de4%ee! f f%eed " 3it 1t a#& !ta'ilit& i!!1e!6

. 8' '/: , /3# %'/#3

57


78/95

Fi4 ,6.. =% $idi#4 C #!t%ai#t! # E#ti%e Ba!e f Ba!e F%a"e

Fi4 ,6.- C #!t%ai#t! # O#e =a%t f Ba!e F%a"e

D": "" O F "" &

58


79/95

T e a!!1"0ti # i! t at t e 'a!e f%a"e i! fi?ed # a 5 #5%ete 'l 596 S all t e de4%ee

f f%eed " 3ill 'e * (


80/95

R #%#' />

• Tilt! f %3a%d a#d 'a593a%d (0it5 i#4)

• S3i$el! left a#d %i4 t (&a3i#4)

• =i$ t! !ide t !ide (% lli#4)6

4! ABAQUS

A?%; 3 i! a !1ite f 0 3e%f1l e#4i#ee%i#4 !i"1lati # 0% 4%a"! 'a!ed # t e fi#ite

ele"e#t "et d7 ! ld '& Da!!a1lt S&!te"! a! 0a%t f t ei% SIMULIA =% d15t Life 5&5le

Ma#a4e"e#t (=LM) ! ft3a%e t l!6 A'a21! i! a ! ft3a%e !1ite f % fi#ite ele"e#t a#al&!i! a#d

5 "01te% aided e#4i#ee%i#46 It i! a ! ft3a%e a00li5ati # 1!ed f % ' t t e " deli#4 a#d

a#al&!i! f "e5 a#i5al 5 "0 #e#t! a#d a!!e"'lie! (0%e 0% 5e!!i#4) a#d $i!1ali


81/95

5 "0 #e#t! (5 10led t e%"al ele5t%i5al a#al&!e!)7 a5 1!ti5!7 ! il "e5 a#i5! (5 10led

0 %e fl1id !t%e!! a#al&!e!)7 a#d 0ie< ele5t%i5 a#al&!i!6

A'a21! ffe%! a 3ide %a#4e f 5a0a'ilitie! f % !i"1lati # f li#ea% a#d # #li#ea% a00li5ati #!6 =% 'le"! 3it "1lti0le 5 "0 #e#t! a%e " deled '& a!! 5iati#4 t e

4e "et%& defi#i#4 ea5 5 "0 #e#t 3it t e a00% 0%iate "ate%ial " del! a#d

!0e5if&i#4 5 "0 #e#t i#te%a5ti #!6 I# a # #li#ea% a#al&!i! A'a21! a1t "ati5all&

5 !e! a00% 0%iate l ad i#5%e"e#t! a#d 5 #$e%4e#5e t le%a#5e! a#d 5 #ti#1all&

ad81!t! t e" d1%i#4 t e a#al&!i! t e#!1%e t at a# a551%ate ! l1ti # i! 'tai#ed

effi5ie#tl&6

Stati5 a! 3ell a! da"i5 a#al&!i! 5a# 'e 0e%f %"ed6

4! !2 A?%; 3 A/%+


82/95

Fi4 ,6., A'a21! A#al&!i! Se21e#5e

A'a21! i! 1!ed i# t e a1t " ti$e7 ae% !0a5e7 a#d i#d1!t%ial 0% d15t! i#d1!t%ie!6 T e

0% d15t i! 0 01la% 3it a5ade"i5 a#d %e!ea%5 i#!tit1ti #! d1e t t e 3ide "ate%ial " deli#4

5a0a'ilit&7 a#d t e 0% 4%a" ! a'ilit& t 'e 51!t "i


83/95

F ll 3i#4 t e "e! 5%eati # t e "e5 a#i5al 0% 0e%tie! f t e ele"e#t! f t e '8e5t!

i#$ l$ed "1!t 'e !0e5ified6 T e!e a%e t e Y 1#4Q! " d1l1! f ela!ti5it&7 = i!! #Q! %ati 7 Ma!!

de#!it& a#d Yield !t%e#4t 6 T ei% "a4#it1de a#d %ie#tati # 0e% ele"e#t a#d !0atial $a%iati #

3it i# t e " del a! !i4#ifi5a#t i"0li5ati #! f % t e %e!1lt! f a# FEA6

S "e f t e "ate%ial 0% 0e%tie! t at a%e #eeded f % a#al&!i! a%e

• Yield St%e#4t - * M=a

• Y 1#4 ! M d1l1! -*- ** M=a

• = i!! # ! Rati *6+

• Ma!! De#!it& 6 Z.* t ##e!/"" +

T e diffe%e#t 3ei4 t! a5ti#4 # t e 'a!e f%a"e a%e

•

Ca# 0& +**94! (*6+ t ##e!)

• E#4i#e +.*94! (*6+. t ##e!)

• Alte%#at % - *94! (*6- t ##e!)

• F1el Ta#9 .,*94! (*6., t ##e!)

Afte% " deli#4 t e 4e#!et 'a!e %ail7 it i! t e# t%ied f % a#al&!i! i# A'a21!6 I# t e

a#al&!i!7 if t e%e a%e a#& e%% %!7 t e file i! 5 e59ed a#d t e e%% %! a%e de'144ed a#d a4ai#

t%ied f % a %1# i# t e ! ft3a%e6 O#5e t e %1# a! 5 "0leted7 0 !t 0% 5e!!i#4 i! e?e51ted6 I#

0 !t 0% 5e!!i#47 S ea% Ca0a5it& a#d =e%5e#ta4e Sli0 a%e 5 e59ed i# 4%a0 !6 T e a55e0ta#5e

li"it f % S ea% Ca0a5it& i! a#d f % =e%5e#ta4e Sli0 i! * 6 T i! a55e0ta#5e li"it i!

0l tted i# t e i#di$id1al 4%a0 ! a#d t e t e% $al1e! f % ea5 ' lt a%e 0l tted i# ea5 4%a0 6 If

a#& ' lt 5% !!e! t e a55e0ta#5e li"it 0l t7 t e# t e ' lt "a& 'e 5 #!ide%ed t fail6

63


84/95

C a0te%

Re!1lt! A#d C #5l1!i #!


85/95


86/95

G-L % )M12

B1

M12

B2

M12

B

M12

B4

M12

B5

M12

B6

M12

B7

M12

BC

M10

B

M10

B10

M10

B11

M10

B12

*6. ++6+* +,6 * ++6+* ++6+* ++6+* ++6+* ++6+* ++6+* ,,6 * ,.6 * ,.6 * ,,6 *

*6- ++6+* +,6 * ++6+* ++6+* ++6+* ++6 * ++6+* ++6+* , 6 * ,*6,* ,*6,* , 6 *

*6+ ++6+* +,6 * ++6+* ++6+* ++6+* ++6 * ++6+* ++6+* , 6 * ,.6** ,.6** , 6 *

*6, ++6+* +,6 * ++6+* ++6+* ++6+* ++6 * ++6 * ++6+* , 6 * ,.6** ,.6** , 6 *

*6 ++6+* + 6 * ++6+* ++6+* ++6+* +,6,* ++6 * ++6+* , 6 * ,.6** ,.6** , 6 *

*6 ++6+* + 6 * ++6+* ++6+* ++6+* +,6,* +,6,* ++6+* , 6 * ,.6** ,.6** , 6 *

*6++6+* + 6 * ++6+* ++6+* ++6+* +,6,* +,6,* ++6+* , 6 * ,.6 * ,.6 * , 6 *

*6 ++6+* + 6 * ++6+* ++6+* ++6+* +,6 * +,6,* ++6+* , 6 * ,-6+* ,-6+* , 6 *

*6 ++6+* + 6 * ++6+* ++6+* ++6+* +,6 * +,6 * ++6+* , 6 * ,-6+* ,-6+* , 6 *

. ++6+* + 6 * ++6+* ++6+* ++6+* +,6 * +,6 * ++6+* , 6 * ,-6+* ,-6+* , 6 *

Ta'le 6- Sli0 $al1e! i# 0e%5e#ta4e 'tai#ed f% " a'a21! %e!1lt!

T e!e %e!1lt! a%e # 3 0l tted i# 4%a0 ! 3 i5 a%e a! !ee# 'el 36 T e [ A?i! $al1e!

a%e t e 4%a$it& $al1e! i# !te0! a#d Y A?i! $al1e! a%e 0e%5e#ta4e $al1e! ta9e# f% " * t % 14

.**6 G%a0 ! f % diffe%e#t !i


87/95

Fi4 6. G%a0 f % =e%5e#ta4e S ea% Ca0a5it& f % M.- ' lt!

Fi4 6- "ed G%a0 f =e%5e#ta4e S ea% Ca0a5it& f % M.- B lt

T e a55e0ta#5e li"it f % ! ea% 5a0a5it& i! 3 i5 5a# 'e !ee# i# t e 4%a0 # t e

t 06 M.- ' lt! 3 i5 fi? t e e#4i#e a%e #1"'e%ed f% " . t % 14 a! :B lt . t B lt ; a!

t e& a%e ei4 t i# #1"'e%6 T e& 5lea%l& d # t e?5eed t e li"it a! !ee# i# fi41%e 6.6 He#5e7 it

5a# 'e 5 #5l1ded t at t e M.- ' lt! d # t ! ea% a#d t 1! a%e !afe6

Fi4 6+ G%a0 f % =e%5e#ta4e S ea% Ca0a5it& f % M.* ' lt!

63


88/95

Fi4 6, "ed G%a0 f =e%5e#ta4e S ea% Ca0a5it& f % M.* B lt

B lt! f !i


89/95


90/95


91/95

Fi4 6 Ba!e F%a"e =l t

Fi4 6.* Se5ti # @ie3 f M.- B lt! it A'1t"e#t!

Fi4 6.. Se5ti # @ie3 f M.* B lt! it A'1t"e#t!

F% " a' $e 5 #5l1!i #! "ade7 all t e M.* a#d M.- ' lt! (MS "ate%ial) a%e 3a&

'e& #d t e li"it i# eit e% 5a!e f S ea% Ca0a5it& a#d Sli07 it 5a# 'e !aid t at t e!e ' lt!

ldi#4 t e e#4i#e a#d %adiat % a%e !t% #4 e# 14 t 3it !ta#d t e !t%e!!e! a#d a%e !afe f% "

faili#47 t 1! 0% $idi#4 a# effi5ie#t 8 i#t6 It 5a# al! 'e t e%ef %e e!ta'li! ed t at all t e

5 "0 #e#t! a%e %ead& t 0e%ate 1#de% t i! l adi#46

67


92/95

F # " S " 9>

T e t %21e a00lied t t e ' lt! i# %de% t a5 ie$e t e e?a5t 5la"0i#4 f %5e/0%el ad

3a! a00lied '& a 3%e#5 6 T i! 3 1ld i#51l5ate 1"a# e%% %7 t l e%% % i# a5 ie$i#4 t e

de!i%ed 0%el ad6 A #e3 !et f :Di%e5t Te#!i # I#di5at %; ' lt! a%e a$aila'le i# t e "a%9et7

3 e%ei#7 a# 0e%at % 5a# $i!1all& !ee if t e de!i%ed 5la"0i#4 f %5e a! 'ee# 'tai#ed % # t6

T i! ' lted 8 i#t a#al&!i! 3a! d #e '& ta9i#4 a# a00% ?i"ate 5e#te% f 4%a$it& f %

0% $idi#4 t e e#4i#e a#d %adiat % 5 "'i#ed "a!!6 T e%ef %e7 t e %e!1lt! t 3e%e

a00% ?i"ate6 B& ta9i#4 t e e?a5t 5e#te% f 4%a$it&7 0%e5i!e %e!1lt! 5a# 'e 'tai#ed6

I#5l1di#4 !e$e%al t e% fa5t %! li9e t e e?a5t a" 1#t f $i'%ati #! t%a#!fe%%ed t t e

' lt! 3 1ld al! el0 !i"1late t e # !ite !it1ati #!6

Fi#e% "e! 3 1ld &ield a "15 0%e5i!e %e!1lt6 T i! "ea#! a ti"e t%ade ff a! t 'e

d #e a! %1##i#4 t e file f % a#al&!i! 3it " %e #1"'e% f ele"e#t! 3 1ld %e21i%e " %e

a" 1#t f ti"e6

Fati41e a#al&!i!7 if d #e7 5 1ld al! tell t e 1!e% e?t%a !et f i#f %"ati # li9e t e

fati41e life f t e 8 i#t6

F'/%+ A33"&?+" G"/3"#

T e i#01t! f% " t e de!i4# a#d a#al&!i! (li9e t e !i


93/95

Fi4 6.- Fi#al A!!e"'led Ge#!et

Fi4 6.+ B lt! H ldi#4 E#4i#e

A! 0e% t e i#01t!7 ' lt! f !0e5ified !i


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REFEREN,ES

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