Strength analysis of welded joints in support structures of heavy machinery subjected to changeable loading conditions

Smolnicki, Tadeusz; Sokolski, Piotr

doi:10.17531/ein/175889

Artykuł - szczegóły

Tytuł artykułu

Strength analysis of welded joints in support structures of heavy machinery subjected to changeable loading conditions

Autorzy

Smolnicki Tadeusz , Sokolski Piotr

Treść / Zawartość

Pełne teksty:

Pobierz

Identyfikatory

DOI

10.17531/ein/175889

Warianty tytułu

Języki publikacji

Abstrakty

The durability of bearing units of large machines depends mainly on the condition of their welded joints. With this in mind, we developed numerical models of the analyzed bearing units, for which we performed FEM simulations of the stresses in welded joints inseveral basic load cases. In each of the respective variants the technical condition of the bearing nodes was different and it corresponded to the severity of the degradation processes. Different positions of the superstructure in relation to the undercarriage were also taken into account. The simulations used the hot-spot method dedicated to FEM analyses of complex welded structures. We discovered that the loads have a significant influence on the values and distribution of von Mises principal stresses and their axial components. Based on the carried out analyses, we identified the most unfavorable load cases that generate the highest stresses in the welded joints of the assessed nodes. We also demonstrated that the applied method effectively assesses the stresses of welded joints subjected to variable working loads.

Słowa kluczowe

fatigue welded joint bucket wheel excavator finite element method heavy-duty machine

Wydawca

Polskie Naukowo-Techniczne Towarzystwo Eksploatacyjne

Czasopismo

Eksploatacja i Niezawodność

Rocznik

2024

Tom

Vol. 26, no. 1

Strony

art. no. 175889

Opis fizyczny

Bibliogr. 48 poz., fot., rys., tab., wykr.

Twórcy

autor

Smolnicki Tadeusz

tadeusz.smolnicki@pwr.edu.pl

Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, Poland

https://orcid.org/0000-0003-3917-9952

autor

Sokolski Piotr

piotr.sokolski@pwr.edu.pl

Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, Poland

https://orcid.org/0000-0003-2407-7988

Bibliografia

1. Al-Karawi H, von Bock und Polach RUF, Al-Emrani M. Fatigue crack repair in welded structures via tungsten inert gas remelting and high frequency mechanical impact. J Constr Steel Res. 2020 Sep 1;172, https://doi.org/10.1016/j.jcsr.2020.106200.
2. Al-Karawi H, von Bock und Polach RUF, Al-Emrani M. Fatigue life extension of existing welded structures via high frequency mechanical impact (HFMI) treatment. Eng Struct. 2021 Jul 15;239, https://doi.org/10.1016/j.engstruct.2021.112234.
3. Al-Karawi HA. Fatigue life estimation of welded structures enhanced by combined thermo-mechanical treatment methods. J Constr Steel Res. 2021 Dec 1;187, https://doi.org/10.1016/j.jcsr.2021.106961.
4. Al Zamzami I, Susmel L. On the accuracy of nominal, structural, and local stress based approaches in designing aluminium welded joints against fatigue. Int J Fatigue. 2017 Aug 1;101:137–58, https://doi.org/10.1016/j.ijfatigue.2016.11.002.
5. Amarir I, Mounir H, Marjani A El. Effect of Temperature and Thickness of the Weld Bead on the Durability of Welded Rectangular Profiles under Damped Loads for Electrical Vehicles Utilization. 2018 6th International Renewable and Sustainable Energy Conference (IRSEC), Rabat, Morocco, 2018, pp. 1-6, https://doi.org/10.1109/IRSEC.2018.8702834.
6. Babiarz S, Dudek, D. Chronicle of failures and catastrophes of basic machinery in the Polish open-pit mining industry. Wroclaw University of Science Publishing House: Wrocław, Poland, 2007. (In Polish).
7. Bošnjak S, Pantelić M, Zrnić N, Gnjatović N, Dordević M. Failure analysis and reconstruction design of the slewing platform mantle of the bucket wheel excavator O&K SchRs 630. Eng Fail Anal. 2011 Mar;18(2):658–69, https://doi.org/10.1016/j.engfailanal.2010.09.035.
8. Cheng B, Abdelbaset H, Tian L, Li HT, Su Q. Hot spot stress investigation on rib-to-deck-to-floor beam connections in UHPC reinforced OSDs. J Constr Steel Res. 2021 Apr 1;179, https://doi.org/10.1016/j.jcsr.2020.106517.
9. Cui C, Zhang Q, Bao Y, Bu Y, Luo Y. Fatigue life evaluation of welded joints in steel bridge considering residual stress. J Constr Steel Res. 2019 Feb 1;153:509–18, https://doi.org/10.1016/j.jcsr.2018.11.003.
10. Dudek D. Kanczewski P. Sokolski M. Experimental analysis of ring girder fatigue of a bucket wheel excavator. In: Development of fundamentals of construction, operation and testing of heavy working machinery -including construction machinery. I Conference of the Central Basic Research Program, Part 1. Scientific Papers of the Institute of Construction and Operation of Machinery of Wrocław University of Science. Conferences; No. 13, pp. 97-105, Wrocław, 1987. (In Polish).
11. Dudek D, Rusiński E, Sokolski M, Włodarczyk J. Stress analysis of ring girder of steel structure of KWK 1500s chassis on the basis of strain gauge measurements of stress course and local displacements: Part II. Performance testing of the ring girder KWK 1500s. Reports of the Institute of Construction and Operation of Machinery of Wrocław University of Science. SPR No. 57, Wrocław, 1985. (In Polish).
12. Feng L, Qian X. A hot-spot energy indicator for welded plate connections under cyclic axial loading and bending. Eng Struct. 2017 Sep 15;147:598–612, https://doi.org/10.1016/j.engstruct.2017.06.021.
13. Fueki R, Takahashi K. Prediction of fatigue limit improvement in needle peened welded joints containing crack-like defects. International Journal of Structural Integrity. 2018;9(1):50–64, https://doi.org/10.1108/IJSI-03-2017-0019.
14. Fuštar B, Lukačević I, Dujmović D. Review of Fatigue Assessment Methods for Welded Steel Structures. Vol. 2018, Advances in Civil Engineering. Hindawi Limited; 2018, https://doi.org/10.1155/2018/3597356.
15. Fuštar B, Lukačević I, Skejić D, Lukić M. Two-stage model for fatigue life assessment of high frequency mechanical impact (HFMI) treated welded steel details. Metals (Basel). 2021 Aug 1;11(8),https://doi.org/10.3390/met11081318.
16. Gnjatović N, Bošnjak S, Stefanović A. Analysis of the Dynamic Response as a Basis for the Efficient Protection of Large Structure Health Using Controllable Frequency-Controlled Drives. Mathematics. 2023 Jan 1;11(1), https://doi.org/10.3390/math11010154.
17. Grabowski P, Jankowiak A, Marowski W. Fatigue lifetime correction of structural joints of opencast mining machinery. Eksploatacja i Niezawodnosc -Maintenance and Reliability 2021; 23 (3): 530–539, https://doi.org/10.17531/ein.2021.3.14.
18. Hobbacher AF. The new IIW recommendations for fatigue assessment of welded joints and components -A comprehensive code recently updated. Int J Fatigue. 2009 Jan;31(1):50–8, https://doi.org/10.1016/j.ijfatigue.2008.04.002.
19. Hobbacher AF. New developments at the recent update of the IIW recommendations for fatigue of welded joints and components. Steel Construction. 2010 Dec;3(4):231–42, https://doi.org/10.1002/stco.201010030.
20. Hobbacher AF. IIW Collection Recommendations for Fatigue Design of Welded Joints and Components [Internet]. Berlin: Springer International Publishing; 2015. Available from: http://www.springer.com/series/13906, https://doi.org/10.1007/978-3-319-23757-2
21. Iqbal N, Fang H, Naseem A, Kashif M, De Backer H. A numerical evaluation of structural hot-spot stress methods in rib-to-deck joint of orthotropic steel deck. Applied Sciences (Switzerland). 2020 Oct 1;10(19):1–19, https://doi.org/10.3390/app10196924.
22. Jiang W, Xie X, Wang T, Zhang X, Tu ST, Wang J, Zhao X. Fatigue life prediction of 316L stainless steel weld joint including the role of residual stress and its evolution: Experimental and modelling. Int J Fatigue. 2021 Feb 1;143, https://doi.org/10.1016/j.ijfatigue.2020.105997.
23. Kombayev K, Muzdybayev M, Muzdybayeva A, Myrzabekova D, Wieleba W, Leśniewski T. Functional Surface Layer Strengthening and Wear Resistance Increasing of a Low Carbon Steel by Electrolytic-Plasma Processing. Strojniski Vestnik -Journal of Mechanical Engineering. 2022;68(9):542–51, https://doi.org/10.5545/sv-jme.2022.147.
24. Królicka A, Radwański K, Kuziak R, Zygmunt T, Ambroziak A. Microstructure-based approach to the evaluation of welded joints of bainitic rails designed for high-speed railways. J Constr Steel Res. 2020 Dec 1;175, https://doi.org/10.1016/j.jcsr.2020.106372.
25. Kumar H, Thakur M, Raj J, Baghel A. A Review on Fatigue Life Estimation of Welded Joints. IJSTE [Internet]. 2018;Volume 4(Issue 7):24–31. Available: www.ijste.org
26. Lachowicz MM, Leśniewski T, Lachowicz MB. Effect of Dual-stage Ageing and RRA Treatment on the Three-body Abrasive Wear of the AW7075 Alloy. Strojniski Vestnik -Journal of Mechanical Engineering. 2022;68(7–8):493–505, https://doi.org/10.5545/sv-jme.2022.142.
27. Łagoda T, Głowacka K. Fatigue life prediction of welded joints from nominal system to fracture mechanics. Int J Fatigue. 2020Aug 1;137, https://doi.org/10.1016/j.ijfatigue.2020.105647.
28. Lee JM, Seo JK, Kim MH, Shin SB, Han MS, Park JS, Mahendran M. Comparison of hot spot stress evaluation methods for welded structures. International Journal of Naval Architecture and Ocean Engineering. 2010 Dec;2(4):200–10, https://doi.org/10.2478/IJNAOE-2013-0037.
29. Leitner M, Simunek D, Shah SF, Stoschka M. Numerical fatigue assessment of welded and HFMI-treated joints by notch stress/strain and fracture mechanical approaches. Advances in Engineering Software. 2016 Jan 1;120:96–106, https://doi.org/10.1016/j.advengsoft.2016.01.022.
30. Lihavainen VM, Marquis G. Fatigue life estimation of ultrasonic impact treated welds using a local strain approach. Steel ResInt. 2006;77(12):896–900, https://doi.org/10.1002/srin.200606478.
31. Liu R, Ji B, Wang M, Chen C, Maeno H. Numerical Evaluation of Toe-Deck Fatigue in Orthotropic Steel Bridge Deck. Journal of Performance of Constructed Facilities. 2015 Dec;29(6), https://doi.org/10.1061/(ASCE)CF.1943-5509.0000677.
32. Liu S, Liu Y. Summary of research on fatigue life assessment of welded joints. J. Phys.: Conf. Ser.1303012002 2019, https://doi.org/10.1088/1742-6596/1303/1/012002
33. Manai A. A framework to assess and repair pre-fatigued welded steel structures by TIG dressing. Eng Fail Anal. 2020 Dec 1;118, https://doi.org/10.1016/j.engfailanal.2020.104923.
34. Mikkola E, Remes H, Marquis G. A finite element study on residual stress stability and fatigue damage in high-frequency mechanical impact (HFMI)-treated welded joint. Int J Fatigue. 2017 Jan 1;94:16–29, https://doi.org/10.1016/j.ijfatigue.2016.09.009.
35. Milenović I, Bošnjak S, Gnjatović N, Obradović A. Bucket wheel excavators with a kinematic breakdown system: Identification a monitoring of the basic parameters of static stability of the slewing superstructure. Eksploatacja i Niezawodnosc - Maintenance and Realibility 2022: 24(2), https://doi.org/10.17531/ein.2022.2.17.
36. Nazzal SS, Mikkola E, Yıldırım HC. Fatigue damage of welded high-strength steel details improved by post-weld treatment subjected to critical cyclic loading conditions. Eng Struct. 2021 Jun 15;237, https://doi.org/10.1016/j.engstruct.2021.111928.
37. Niewczas A, Mórawski Ł, Rymarz J, Dębicka E, Hołyszko P. Operational risk assessment model for city buses. Eksploatacja i Niezawodnosc -Maintenance and Reliability 2023: 25(1), https://doi.org/10.17531/ein.2023.1.14.
38. Rosik R. Methodology of evaluation of degradation processes of rail nodes of rotation of bodies of working machines. [Wrocław]: (PhD Thesis), Wrocław University of Science; 2007 (in Polish).
39. Smolnicki T. Physical Aspects of the Coherence Between the Large-Size Rolling Bearings and Deformable Support Structures. Wrocław University of Technology Publishing House. Wrocław, Poland, 2002. (In Polish).
40. Smolnicki T. Large-Size Slewing Joints: Global and Local Issues. Wrocław University of Technology Publishing House: Wrocław, Poland, 2013. (In Polish).
41. Sokolski P, Smolnicki T. A method for monitoring the technical condition of large-scale bearing nodes in the bodies of machines operating for extended periods of time. Energies 2021; 14 (19): article number 6637, https://doi.org/10.3390/en14206637.
42. Szala G, Ligaj B. Analysis of a Simplified Method for Determining Fatigue Charts Δs-N on the Example of Welded and Soldered Connectors. Polish Maritime Research. 2018 Jun 1;25(2):92–9, https://doi.org/10.2478/pomr-2018-0059.
43. Śledziewski K. Fatigue assessment for selected connections of structural steel bridge components using the finite elements method. In: AIP Conference Proceedings. American Institute of Physics Inc.; 2018, https://doi.org/10.1063/1.5019154.
44. Taheri S, Fatemi A. Fatigue crack behavior in power plant residual heat removal system piping including weld residual stress effects. Int J Fatigue. 2017 Aug 1;101:244–52, https://doi.org/10.1016/j.ijfatigue.2016.11.004.
45. Tang L, Ince A, Zheng J. Numerical modeling of residual stresses and fatigue damage assessment of ultrasonic impact treated 304L stainless steel welded joints. Eng Fail Anal. 2020 Jan 1;108, https://doi.org/10.1016/j.engfailanal.2019.104277.
46. Vantadori S, Giordani F, Fortese G, Iturrioz I. Hot-spot localisation according to the critical plane-based approach. Int J Fatigue. 2018 Nov 1;116:669–76, https://doi.org/10.1016/j.ijfatigue.2018.06.008.
47. Wang Q, Ji B, Fu Z, Ye Z. Evaluation of crack propagation and fatigue strength of rib-to-deck welds based on effective notch stress method. Constr Build Mater. 2019 Mar 20;201:51–61, https://doi.org/10.1016/j.conbuildmat.2018.12.015.
48. DIN 22261-1. Excavators, spreaders and auxiliary equipment in opencast lignite mines -Part 1: Construction, commissioning and monitoring.

Typ dokumentu

Bibliografia

Identyfikator YADDA

bwmeta1.element.baztech-380b008c-1cb7-4172-b9e1-a9be71047220