Fatigue Assessment of Ship Structures using Hot Spot Stress and
Structural Stress Approaches with Experimental Validation
Myung Hyun Kim (M), Pusan National University, Seong Min Kim (StM), Pusan National University, Jae Myung Lee
(M), Pusan National University, and Sung Won Kang (M), Pusan National UniversityThe aim of this study is to investiate fatigue assessment of typical ship structures employing structural stress approach and to compare with hot spot stress approach. As an initial study of the systematic validation efforts on structural stress method, an experimental investigation is performed on a series of edge details with welded gusset plates. Extrapolation based hot spot stress using converged mesh were also calculated for each specimen types.
Having validated the application of structural stress for small edge detaIls, a systematic investigation is carried out fora fatigue assessment of typical ship structures employing structural stress approach. Fatigue strength of side shell
connection of a 8,100 TEU container vessel is evaluated using hot spot stress and structural stress employing
simpl/Iedfatigue analysis.
KEY WORDS: Ship structures, welded structure, fatigue
design, structural stress, hot spot stress, fatigue
life, finite element analysisNOMENCLATURE
a
: Fatigue crack lengthC : Material constants for crack propagation model
d
: Nodal displacementD Accumulated fatigue damage
f,, and f2 : Line force with respect to x, y and z axis
F
: Vector of nodal forceF :Nodal force with respect to mid-plane of thickness
and F
: New balanced force with respect to x, y andzaxis
Weibull stress range shape distribution parameter for load condition n
¡(r)
: Dimensionless function of rK : Stress intensity factor Element stiffness matrix
M,,, : Notch induced stress intensity magnification factor
n0 : Total number of stress cycles associated with the
stress range level ic
nj
Fatigue life ¡ : Element lengthr
Bending ratio( rYb / o)SCF
: Stress concentration factort : Plate thickness (mm)
Weibull stress range scale distribution parameter for
load condition n
Average correlation between sea, pressure loads and internal pressure loads
Paper No. Year- Last (family) name of the first author c.s HS Top °Bollom o-n °g1 o-w,
/t
eq Lc7 &Tg AOhg Ao;Average correlation between vertical and horizontal
wave induced bending stress Bending stress (MPa)
Amplitude of stress due to dynamic external sea
pressure loadsAmplitude of stress due to dynamic internal pressure loads
Membrane stress (MPa) Structural stress (MPa) Hot spot stress (MPa) Measured stress at top surface Measured stress at bottom surface Nominal stress (MPa)
Bending stress of deck structure due to torsional
deformation of hatchWarping stress due to torsión at position considered Usage factor
Equivalent structural stress (MPa) Stress ranges
Global combined stress range (MPa)
Range of stress due to wave induced horizontal hull
girder bending moment (MPa) Local combined stress range (MPa)
Reference stress range value at the local
detail exceeded once of n0 cyclesRange of stress due to wave induced vertical hull
girder bending moment (MPa)
Deift University of Technology
Ship HydromeChafl
LaboratorY
Library
Mekelweg 2, 2628 CD Deift
The Netherlands
INTRODUCTION
Welding is the
most commonly employed
process forfabricating steel structural joints, including those of ships and offshore structures. Some of the advantages of welding are relative ease of fabrication, high joint efficiency and water tightness (Matsubuchi 1980). However, stress concentrations
due to the weld
itself and because joints
are generallydiscontinuous portions of a structure, welded joints tend to
suffer fatigue damage before other structural elements. Because,
the fatigue
lifeof a structure's welded joints
isa key
determinant of the service life of a structure subject to cyclic
loading, it is very important to predict the fatigue life of welded
joints in an accurate manner. The fatigue life of welded jòints depends on various factors such as weld quality and surface
finish, and thejoint geometry and stress states
Currently there exist three different methods for fatigue design; stress-based approach,
strain-based approch and
fracturemechanics approach (Cui 2002). Within the scope of stress-' based approach, different stress definition can be used such as
nominal stress, hot spot stress and structural stress. While
nominal stress is the most widely used in fátigue design, it is difficult to define nominal stress value for çomplex structures such as ships (Maddox 1991). Hot spot stress is defined as astress value obtained by extrapolating stresses at certain distance from the weld toe based on finite element analysis (Niemi 1999).
While hot spot stress approach is well accepted in offshore industry, it is well recognized that hot spot stress values may
vary for different elements and different extrapolation
techniques. On the other hand, structural tress approach is recently proposed, and it is known as mesh-size insensitive
fatigue assessment method by using finite element analyses. The structural stress definition is based on the elementary structural mechanics theory and is known to provide an effective measure of a stress state in front of weld toe (Dong 2001).
The aim of this study is to investigate fatigue assessment of
typical ship structures employing structural stress approach and
to compare with hot spot stress approach. As an iñitial part of
the systematic validation efforts on Battelle's structural stress method, a detailed experimental investigation is performed on
edge fatigue details as a part of B attelle lIP program (Kang et al. 2004).
The S-N data generated from this investigation have shown that
the structural stress based SCF (Stress Concentration Factors) are effective in correlating not only the S-N' data generated in this detailed experimental investigation, but also all other S-N data from other joint types collected from various fatigue test literatures. Extrapolation based hot spot stresses (HSS) using
converged mesh were also calculated for each specimen types. Within the edge details tested in this investigation, the hot spot
stresses based on three different extrapolation procedures are compared and found to provide a good correlation of the S-N
data. In the present work,
hence, two
different fatigue assessment procedures using hot spot stress and structural stressare compared and validated based on the series of fatigue test
data within similar jointtypes and thicknesses.
Having validated the application of structural stress for small
edge details, a systematic investigation is carried out for a
fatigue assessment
of typical
ship structures employing structural stress approach. Fatiguestrength of side
shell connection of an 8,100 TEU containervessel is evaluated usingboth hot spOt stress and structural stress. Simplified fatigue analysis is applied using typical lòading conditions defined by
classification societies. Finite element analysis is carried out for full ship with respect to fatigue damage prone locations such as side-longitudinal located near design draft Fatigue life
calculated using structural stress is compared with that of hot spot stress approach. For fatigue strength assessment of ships, structural stress approach is found to be a viable alternative as employing the mesh size insensitive charaçteristics. Further study for the fatigue strength assessment of ship and offshore
structures are required with different mesh sizes and shapes.
COMPARISON OF STRUCTURAL STRESS
AND HOT SPOT STRESS
Structura! stress definition
As shown
in Fig. 1,a typical
through-thickness stressdistribution at the fillet weld toe is assumed to exhibit a
monotonic through-thickness distribution with the peak stress occurring at the weld toe (Niemi 1999). The self-equilibratingstress
state induced by local geometry or notch effect
isconsidered to be included in S-N data.
Fig. I Through-thickness structural stress distribution
The corresponding equivalent structural stress distribution is illustrated in Fig. 2, in the form of a membrane component
(0m) and bending component (ab). The normal structural
stress (a5 ) is defined at a location of interest such as sectionA-A at the weld toe in Fig. 2 with a plate thickness of t. The
normal and shear stress at the reference section B-B can bereadily obtained from either a finite element solutjon or
measurements using strain gauges. The distance, 6, representsthe distance between sections A-A and B-B at the weld toe.
The structural stress components am and ab can be calculated
;: Locui SfreB Diatributions alongA-A
>x
Fig. 2 Illustration of structural stress measurement
The strain gauge measurements obtained from the strain gauge pairs located both at the top and bottom edges of the specimens
was used to calculate the stnictural stress by means of Eq. (4).
Note that the first and the last strain gauges were not used since
they tend to exhibit more variability than the remaiñing strain gauge measurements. The variation in the measured structural
stresses is due to the variations in the surface stresses measured, which are unavOidable in typical strain gauge based
measurements. To reduce the effects of the variation
inestimating stress values at the weld toe, averaged values
between the symmetric gauges in left and right sides of the test specimens are used. In addition, a linear regression can then beused to represent the averaged strain distributions. The strain values based on the linear regression at each of the gauge pair
positions can then be used in Eq. (4) to determine the structural stresses at the weld toe.
Structural stress using fiizite element analysis
In FE analysis using 2-D shell or plate element, balanced nodal
forces can be derived from the element stiffness matrices and
the nodal displacements as described Eq. (5). The same applies
to the derivation of balanced nodal moments ûsing nodal
rotational displacement..
(Fe) = [K]{d} (5)
where (Fe) = vector of nodal forces, [K] = element stiffness
matrix, {d) = nodal displacement
Once the nodal forces (Fr1, F2) in y direction and moments with
respect to x axis are obtained as shown in Fig.
3, thecorresponding line forces (f, f) can be calculated with
consideration of the mechanical equilibrium as derived to Eqs.
(6), (7) and (8). The derivation of line moments (m1, m2) are the same as that of the line forces with respect to the nodal
moments (M1, M2)
+ ff(x)dxO
(6)Paper No. Year- Lst naine of first author Page number
m
0m t2 + 0b t2 =
r
o-(y)ydy
+.5r
(1)
Here the first equation represents the force balance in
x-direction evaluated along B-B section, and the second equationrepresents moment balance with respect to section A-A at yO.
The mesh-insensitive structural stress can be calculated as long as the stress states at two sections at A-A and B-B are related to each other in equilibrium sense (Dong 2001).
Structural stress from measurements
On the other hand, as discussed by Dong et aI. (2004), the
membrane and bending components in thè structural stressdefinition can be estimated by using a series of strain gauges on both top and bottom surfaces, as shown in Fig. 2 for a fillet weld. 1f the two rows of the strain gauges (B-B and C-C) are situated approximately within a linear surface stress distribution regime near the weld toe, the bending stresses at Sections B-B and C-C can be calculated based on the measurements from both top and bottom surfaces as:
-:
(2)
dc
=.(oTOp-It should be noted that if there exists no external loadings
between Sections B-B and C-C, the sectional moment changecan be expressed as:
AM (3)
where I represents the sectional moment :of inertia for unit length in z direction in Fig. 2. Then, the strùctural stress at the
weld (A-A) can be estimated by using extrapolations with
respectto bending stresses at B-B and C-C as:Cb =-:
+(of
n.B)OsYTop+j(Ob 0b)
B L C B(4)
In conjunction with fatigue testing of edge details, detailed
strain gauge measurements are collected before starting fatigue
test. The strain gauge readings were collected at two loading
levels: (1) 20% of nominal yield strength and (2) 50% of
nominal yield strength.F +Jfy(x).xdx=0
fi =(2F1
-Fr2), fy2= (2Mri - M2), m2 = .(2At12 - 1W1)
where ¡ = element size along the weld line as described Fig. 3
Fig. 3 Local line force and the line moment frOm nodal forces
and moments for 4 node shell element
Along a weld line adjacent to multi-elements as shown in Fig. 4, a governing equation is given by Eq. (10) for four (4)-node sell or plate elements. The applied nodal forces are defined using the element local coordinate (x', y', z').
Fig. 4 FE model with weld line using 4 node shell element
6
3_
Once the line force and the line moment are available, the
structural stress at each node can be given by Eq. (11).fy6m
(li)
Where, o, is stress concentration effects due to joint geometry
and °m are membrane and bending stress respectively.
Fatigue life evaluation from equivalent structural
stress and the master S-N curve
Fracture mechanics based prediction of fatigue life in cycles to final failure can be expressed as:
N=
f
daa=aj
C(M,,)(tK)m
(12)where Mb, represents a notch-induced stress intensity magnification factor defined as:
= -¡((wif
'-E"-h Jô,nInotch effects)
K (considering only the far fl/ed stress coñtribution) Rewriting Eq. (12) in terms of relative crack length form as:
aft=I m
N=
i
td(a/t)
1tT(L,iO.$)_mI(r) (14)
C(Mb,)(K)
c
a, It-*O
where ¡(r) is a dimensionless function of r =crb
/o and can be
expressed iii the following form under given m:
¡(r)=
.1
d(a/t)
a fl_)OMbi[fm() - r(J'm(-) -
fb(--)II(15)
Here, the stress intensity factorKwithout notch effects for an
edge crack is considered as:
K
[CTmfm()Tbfh()]
(16)The paranietersfm(a/t) andf,('a./t) are well known dimensionless
function of alt corresponding to the membrane and bending
components, which can be found in various fracture mechanics handbook such as (Tada 1985).
Rearranging Eq. (14) as in
term of
Nwith the given
dimensionless ¡(r) function:I 2-m I
Lo=C rnj 2m I(r)N
(17)An equivalent structural stress can be defined by normalizing
the structural stress range, Eq.
(17), with two variables
expressed in terms of the thickness t and the bending ratio r asfollows: (13) F2 n
!L
!L 3 6!.
(IIl2)
o '2 6 0 (in2 + -o 0 'n-I (10)=0
6 3 L. 6 0 3 'n-I 6 'n-Iwhere the thickness term/2m2m(m=3.6 according to Dong; the
exponent of Paris crack propagation) becomes unity for t= I
(unit thickness) and therefore, the thickness t can be interpreted
a ratio ofactual thickness t to a uñit thickness, rendering the
term dimensionless. With this interpretation, the equivalent JSeq retains a stress unit ¡(r) is the function
of
bending ratio (r) whichindicates corrections depending on loading modes and crack types. Crack types should be classified into an edge crack or a
semi-elliptical crack. As an edge crack grows, 1(r) can be
divided into load-controlled condition and displacementcondition and can be expressed
as Eqs.(19) and (20),
respectively.¡(r)tm =-0.0732r6 +0.2132r5 -0.2063r4 (19)
+O.09lr3 +0.0193r2 -0.014r+l.1029
¡(r)tm = 2.4712r6 - 5.5828r5 + 5.0365r4 (20)
-l.9617r3 +0.4463r2 +0.035r+1.l392
In case ofa semi-elliptical crack, ¡(r) can be divided intothe
function for small detail and for structural joint Approximate
functions are expressed by Eqs. (21) and (22), respectively.
¡(r)tm =0.00llrt +0.0767r5 -0.0988r4 + 0.0946r3 + 0.022 Ir2 + 0.014r + 1.2223
¡(r)tm =2.1549r6 -5.0422r +4.8002r4
-2.0694r3 +0.561r2 +0.097r+1.5426
Since the thickness correction, the loading mode effects and geometrical discontinuities have been already included in Eq.
(18), any type of weld joints or loading modes can be evaluated consistently with the equivalent structural stress. Based on Eq.
(18), over 2000 results ofthe existing fatigue tests for both
various weld joints and loading modes are fitted in Fig. 5 and a
master S-N curve is determined by Ha(2006). Based on Fig. 5,
required parameters for S-N relationship can be obtained as Eq.
(23) and Eq. (24). Here, the design master S-N curve is on the
basis of two standard deviation with respect to mean S-N curve. For the mean master S-N curve, C=2 1672.4, m '=3.08
1ogA=13.33-3.O8logAScq
For the design master S-N curve, C=15465.6, m'3.08
logA,-=1 2.88-3.O8logASeq
where, o and o correspond to measured stresses at 0.5t and
I .5t in distance from the weld toe, respectively, as shown in Fig. 6 (Niemi 1992).
Stress Notch stress
/
Hot spot stress
Extrapolation of geometric stress to
//derive the hot spot stress
1.E.Oß
I
Region effected by the notch stress
Fig. 6 Calculation
of hot
spot stressbased on
linear extrapolationThese hot spot stresses are used for comparison purpose with
structural stress for interpreting fatigue test results in this study.
Paper No. Year - Last name of first author Page number
HS=1.5o (25)
I.EO4 1.E.O5 1.EG
Bsduraece. cycles
Fig. 5 The master S-N curve by using equivalent structural
stress parameter
Hot spot stress
Hot spot stress is the most common to evaluating the fatigue strength in ship and offshore structures because it includes the stress concentration due to geometric shape. There are three
different stress extrapolation techniques as commonly recommended procedures for the calculation of hot spot stresses
in welded structures; 1) the linear extrapolation of stress over
reference points at 0.5 and 1.5 of plate thickness away from the
hot spot; 2) the linear extrapolation of stresses over reference
points at 0.4 and 1.0 of plate thickness away from the hot spot; 3) no extrapolatiòn but the use ofthe stress values at 0.5 of plate
thickness from the hot spot as the relevant hot spot stress
(Mansour 2003). In this study, hot spot stress is calculated using Niemi's guideline based on Eq. (25):tri 3t/2
Distance from hot spot
eq = 2-m I (18)
EXPERIMENTAL PROGRAM
The experimental investigation on edge details was set up to
achieve the following major objectives:
Experimentally veri1,' the structural stresses calculated
using the mesh-insensitive structural stress method
Investigate fatigue crack behavior in edge details, effects of plate thickness and failure
definitions on S-N data
generation
Examine the applications of the extrapolation-based hot spot stress methods in interpreting the S-N data for edge
details
Examine and demonstrate the validity of the structural
stress based master S-N curve approach in interpreting the S-N data for edge details
The detailed experimental investigation was focused on a total of twelve specimen designs of edge details. The specimen
design involves a base plate and gusset attachment plate which
are welded to form an in-plane edge detail. Two different
thicknesses of the base plates were considered, i.e., 10mm and 15mm. The widths for the base plates and the lengths of thegusset plates were varied to obtain a wide range of the hot spot
and structural stresses based stress concentration factors at the weld ends considered as fatigue prone locations. All twelve
specimens (with unique combinations of plate thickness, width,
and thicknesses) were fabricated and tested
in duplicates. Typical shipyard welding procedures were used for fabricatingthe test specimens. Weld leg lengths and distortions in each
fabricated specimen were measured before fatigue testing for the later interpretation of fatigue test data.
Typically, six pairs of strain gauges were used on each side of the specimens. The strain gauge readings corresponding to
approximately linear distribution regime were used to calculate the corresponding structural stresses according to the definitions in the Battelle's structural stress definition and its measurement techniques (Battelle
2004). For
all specimens tested, anexcellent agreement between the measured and calculated
structural stresses has been obtained, l-lot spot stress measurements based on 11W recommendations for edge details
were also calculated from the strain gauge data and compared
with the corresponding S-N curve.
Fully reversed constant amplitude loading conditions were used
for fatigue testing. The frequency of the cyclic load was 3Hz. Typical nominal stress range of I2OMPa was used throughout the test with a cyclic stress ratio of 0.4 under load-controlled conditions. During the fatigue testing of each specimen, both stiffness, defined as load range/displacement range between
grips, as well as instantaneous crack size as a function of cycles
were recorded at a fixed cycle interval. After final failure
defined as the separationof
cross-section separation, photographs of the final fracture surfaces of the failed specimen were also presented as a part of the test record.EXPERIMENTAL SETUP
The dimension of the test specimen is shown in Fig. 7. The steel
plates of thickness of both 10mm and 15mm are used as the thickness of the main plate of test specimens. The grip surface dimension, indicated as dg (85mm) and W (100mm), are kept identical for all specimens. The lengths of gusset plate (L2), which is welded on the side of the base plate, are designed to
vary between 50, 100, 200 and 250 mm.
L,
Fig. 7 Dimensionoftest specimen
The material used in this research is a ship-structural mild steel
of
grade-A. The chemical composition and mechanical properties are summarized in Table 1. The design yield stressof
the material is defined as 235MPa for ship-structural mild steel according to the specifications of classification societies. Table I Major Chemical composition and mechanical propertiesof
(a) (b)
Fig. 8 Grip location: (a) Base plate width 50mm (b) Base plate
width 90mm C(%)Si(%) Si(%) Mn(%) P(%)
0.13 0.17
0.15 0.18
0.46 0.65
0.012 0.019 Yield Stress (MPa) Tensile Stress (MPa) Elongation (%)From Mill Sheet 299 336 441 - 468 28 - 30
From Tensile Test 290 - 299 427 457
34 36
T, T,
a a
Fig. 8 shows a test specimen installed between grips. Note that the gusset plate is always located in the left side. Therefore, the
front side has the gusset plate always in the left side, and the rear side has the gusset plate in the right side. The dimension
matrix for the test specimens used in this study is summarized in Table 2. A series of proposed variations of some dimensions are
also given in the table as well. Table 2 Test matrix
FCAW (Flux Cored Arc Welding) is used to attach the gusset
plate into the main plate. V-shape groove was machined before
weld. Gusset plate and main plate are welded by 3 - 5 passes
under flat position. During welding, additional jigs were
installed to prevent the specimen from any excessive
deformation. After welding the front side and backside, a fillet
welding was formed at the ends of the gusset plates.
Leg lengths of fillet welds at both sides of gusset plates are
recorded using Moire measurement technique. Moldings reflecting the weld bead shapes are obtained using dental silicon
rubber and sliced into 2mm thickness to obtain leg lengths of both the main plate and the gusset plate sides. Average leg lengths of the main plate and the gusset sides are 5.52mm and
5.57mm, respectively.
STATIC LOADING TEST RESULT AND
ANAYSIS
Prior to fatigue test, surface stress distribution both at gusset and
opposite sides are measured with remote nominal stresses at
20% (47MPa) and 50% (1 17.SMPa) of yield stress (235MPa).
Fig. 9 shows the typical placement of strain gauges. The strain gauges near the weld toe are placed either 5mm or 8mm in
distance from the toe. The remaining strain gauges are attached either 8mm or 10mm from each other. The fatigue test machine used in this study is a servo hydraulic fatigue test machine with maximum load capacity of ±20 ton. Before setting a specimen, stress values measured using strain gauges at front and rear sides
of specimen are carefully observed in order to avoid any
possible pre-bending of the specimen.-.-4544aC1 Os.. -4--aV? 02.. -.-La,a? #10 #7 4 54 54 54 54 10 fr t ta gma) 12.10
DtttmIO. fl thi LU? OUI 54 54 C 54 54 lO O
#20 #19 #18 817 #10
.54."8lO54,al 0, + St .541 OSt1
...5po'4 O2.-a.Oøaa54-3 OSt,
O t
54
10 10
54r tho (Qe (Qt
O 14 54 54 C
Fig. 10 Stress distribution of specimens 2-1 and 2-2
a a---*-Sto40Cl O54--Spl OSt
so a OSt: No. TI T2
Li
L2 WI W2 R do 1 10 10 350 50 50 25 45 150 2 10 10 350 100 50 25 45 125 3 10 10 350 200 50 25 45 75 4 10 10 350 250 50 25 45 50 5 10 10 350 50 90 25 145 150 6 10 10 350 100 90 25 145 125 7 10 10 350 200 90 25 145 75 8 10 10 350 250 90 25 145 50 9 15 10 350 50 50 25 45 150 10 15 10 350 100 50 25 45 125 11 15 10 350 200 50 25 45 75 12 15 10 350 250 50 25 45 50 a ,y a 154 ¶54 154 554 118 54 -54 -c 8 'm 54 IS ¶54.. IC 54. 54 5454-I Os-4-' St54554-1 lISt.
lO StO5454554. 9 .O'4? OIS
- 84 84
Paper No. Year - Last naine of first author Page number
24 2424 21 24 19 13 14 15 16 17 18
Sbain ga.Jge Sbain
Fig. 9 Strain gauge locations in 10mm distance
Fig. 10 illustrates the surface stress distribution of the specimen 2 along the edge surface on the base plate. Before cyclic fatigue
testing, each specimen was first tested under static loading
conditions with remote nominal stress at 20% and 50% of yield
strength level, with fully instrumented strain gauges in pairs between both edges of the base plate placed at 5mm from the
weld ends. On the gusset side, 12 strain gauges are placed while
8 strain gauges are being placed on the opposite side. Stress
values obtain from the measurement show similar values for the
duplicate test, e.g. specimen #2-1 and #2-2. Also a symmetric stress distribution is observed for the both sides of the gusset
plate.
Fig. 11 and Fig. 12 present similar result for specimens 6 and 10,
respectively. Fig. 11 corresponds to the stress distribution for the specimen with identical dimension except for the width of
the main plate (90mm), and Fig. 12 is that of the specimen with different thickness of the main plate (15mm).
10 54 54 ¿1
-..-i5n.,,*i O.1-...-inaiaint b
i2..-n-n
Q.S.n n n si C a n n n i s s o g * Distaacc frQmthc
Fig. 11 Stress distribution of specimens 6-1 and 6-2
-.-i.nnosiiß 02. -.--!ainJDi Qi.
-'- taiflaiuI2 02,.- -Snaiaro2 *. -la ti,
#10 .r.Io a o in ii
a a n a a
is t, i Dn from the .; (mm) 12ODistance troni the too (mm)
w n n
n a a
n ai ta i ra ai ai. ow. 'or, to'. a, io g #20 59 618 #17 #16 o'Diotance frani the toe (mon)
T1'lO
.WI 02.'---i.rinntanI ea.
--troeoi12 Q2,-s-aiut3 COr,
-o 'i a s a e so ro a Distance from tilo toe (mm)
Tlnt5
(Unit mm)
Distance from the toe (mm)
i t, t, X a n i. s, n i
#12...#13,. #14....#15.,.
so'
-I-5aC,MorC1C2,,-w-OntnoCit iOr
.,
t- - ¡-n-iDrrnronffi.1 o2,... ps,ob.l bO.eo.J
-la
..
ia --io at.
in
Fig. 12 Stress distribution of specimens 10-1 and 10-2
As noted in the previous section, hot spot stress values may
become different depending on the extrapolation technique used.
For instance, Fig. 13 illustrates hot spot stress obtained for test
specimen #2. Based on the measurement, hot spot stress is found to be 161.O3MPa using the linear stress extrapolation at 0.5 and
1.5 plate thickness. On the other hand, hot spot stresses are calculated as 153.67MPa and 164.S8MPa for extrapolation of (0.5/1.5t) and (0.411.Ot), respectively, based on the stresses
calculated from finite element analysis. It is clearly seen that hot spot stress values exhibit noticeable difference between
153.67MPa and 164.58MPa. This could result in significantly
different fatigue life estimation.
Fig. 13 Hot spot stress calculated from measurement and FE
analysis for test specimen #2
Average stress values measured at distances of 5mm and 15mm from both sides of weld toe are used to obtain hot spot stress. Fig. 14 illustrates the structural stress results based on the strain
gauge measurements for each given strain gauge pairs located both at the top and bottom edges of the specimens by means of Eq. (4) and the hot spot stress obtained by extrapolating the
stresses measured by strain gauges at 5mm and 15mm locations
using Eq. (25) for the specimen 2. It is observed that hot spot stress values are typically higher than structural stress values. Note that the structural stress values using measurements 2, 3
and 4 show a good agreement among each other.
2.6 2.0 1.5 LL C., 0.5 0.0 -u- FE(mesli) -.-TEST#2 '-s' HSS(co anar1 +-- HSS(a00s,)
#2-1 Reg(20%) #2-1 Reg(50%) #2-2 Reg(20%) #2-2 Reg(50%) Fig. 14 Comparison of structural stress (SS) and hot spot stress (HSS) of specimen 2 ai a ioo 'a to' a n ¼ a ai ai 11g 'a-n io n
-S-taintSI lia -.--o'ainSI i
OOsiioO'2 Ca-s grsraiSO O
#1
2... ...
(UnIt mm)
Diotooloc from the toc (mon)
i t ti io a n n n ii a st n
Thsmn from the toc (mm
w n n e go
n n a a
ti ra,g.2i.#19.#i.9 .#1716
...-. i.o nia-1 i -s.. Sgianr-1
ct- -Sioga-2 ta 'X 3.0! 2.51 0.0! 0.51 1.0! 1.5! 2.01 Distancefromweld toe
Fig. 15 and Fig. 16 also present similar results for the specimen
6 and
10, respectively. Stress concentration factors arecompared using both structural
stress and hot spot stress
obtained from strain measurements at two different loadinglevels 2.5 2.0 1.5 u-C., 0.5 25 2.0 1.5 1.0 0.5 0.0
#6-1 Reg(20%) #6.1 Reg(50%) #6-2 Reg(20%) #6-2 Reg(50%)
Fig. 15 Comparison of structural stress (SS) and hot spot stress (HSS) of specimen 6
0.0
#10-1 Reg(20%) #10-1 Reg(50%) #10-2 Reg(20%) #10-2 Reg(50%)
Fig. 16 Comparison of structural stress (SS) and hot spot stress (HSS) of specimen 10
The structural stress and the hot spot stress values for the entire specimen considered in this study are summarized in Table 3. In
general, higher stress concentration values are obtained as the length of gusset plates increases. Similar observation can be made for both structural stress and hot spot stress. Within the
specimen with same gusset lengths, specimens with thicker base plate (15mm) resulted lower stress concentration than that of the specimen with 10mm thickness. Comparing the stress
concentration factors between different width of base plate (50mm and 90mm), it was found that 90mm indicated higher
stress concentration. Also, hot spot stress values obtained from
the measurement show slightly higher values than those of
structural stress. The number indicated as Test-1 and Test-2 in
the table represents the two duplicate tests, respectively.
Table 3 Stress concentration Ñctors of each specimen based on strain measurements
CYCLIC FATIGUE TEST RESULTS AND
ANALYSIS
Crack propagation measurement
Before the fatigue test,
lines were drawn at 1mm uniform
distance using a height gauge for measuring fatigue crack
propagation. The initiation and propagation of crack were
observed at every 5000 cycles corresponding to about every30mm. The crack propagations with respect to fatigue cycle for
the specimen 5-8 are presented in Fig. 17 as a typical example
of the crack propagation. (U) and (L) corresponds to upper part
and lower part of the gusset. And the numbers indicate the
cycles at failure. Essentially, it is found that the crack size of 0.4W corresponds to 10% reduction of stiffness. This stiffness reduction can be used as a failure criterion, particularly usefulfor more complex specimen
configurations and loading conditions. E E a, C a, a) Q 100 90 80- 70- 60-50. 40- 30-20 1 0-297,020(11 327,770(U) 433;910(U) 52 940(L) #6-1... B... 532,820(U).
g 150000 200000 250000 300000 350000 400000 450000 500000 550000 600000 Number of cycleFig. 17 Crack propagation measurement with respect to fatigue cycle for specimen #5 - #8
Specimen
Structural Stress
Test i
Test 2Hot Spot Stress
Test i
Test 2 1 1.04 1.13 - 1.59 2 1.11 1.24 - 1.52 3 - - 1.54 1.72 4 - 1.56 1.70 -5 - 1.21 1.65 -6 1.18 1.20 1.71 1.55 7 - - 1.65 1.94 8 1.38 1.41 1.91 1.84 9 - 1.12 1.32 1.48lo
1.17 1.17 1.56 1.38 11 - - 1.65 1.94 12 1.38 1.28 1.73 1.72 #8-2 #5-2 #8-2 #5-1.F
F ' . .L01-..B BvB
cB
Fracture surface
This section presents the crack initiation location and crack
propagation behavior by observing fracture surfaces of several test specimens after fatigue test. Typically most cracks initiated in the middle
of
weld toe as indicated with an arrow. However, some cracks initiated at the edgeofthe weld bead, while some initiated at multiple sites. In general, the crack initiation sites are strongly depended on the weld bead shape (Suresh 2004). Fig.18 shows the fracture surface
of
the specimen #1-2
(thickness 10mm, width 50mm and gusset length 50mm). It canbe seen that the crack started at the middle
of
the weld bead.Red ink was injected with respect to both surfaces of test
specimen at a regular period. As the crack gradually growsthrough the fatigue test, fracture surface shows an elliptic shape
and then becomes a flat shape through the crack plane. As the
crack reaches approximately half of the width, a brittle fracture occurred.
Fracture surface
Direction of fatigue crack propagation
Fig. 18 Fracture surface and final failure of specimen #1-2
Fatigue life
Fully reversed constant amplitude loading condition was used for the fatigue test. The frequency of the load was 3Hz, and
typical stress ratio R was set to 0.4. The fatigue loading
condition for each specimen is summarized in Table 4.icue test condition for each specimen
Each specimen is tested until final fracture. The stifThess curve
is obtained dividing the load range by the displacement range
based on Eq. (26) using the following relationship.
(Maximum load - Minimum load) (Maximum displacement - Minimum Displacement)
EDX-1 500A memory recorder/analyzer is employed to record
the load and the displacement at every 990 cycles in order to
obtain the stiffness curve. Normally, both load and displacement
are recorded for I second at 100Hz sampling rate. Fig. 19
illustrates a typical stiffness measurement for the specimen 8.
- . - Specimen#8-1 -. -Specimen#8-2 I
(26)
4-2 l2OMPa 10-2 I2OMPa
5-1 l2OMPa Il-1 12OMPa
5-2 l6OMiPa 0.2
lI-2
I2OMPa6-1 I2OMPa 12-1 I2OMPa 0.4 6-2 12OMPa 12-2 12OMPa Spec. Stress Range Stress Ratio Spec. Stress Range Stress Ratio 1-1 IOOMPa 0.4 7-1 I2OMPa 0.4 (a,,,,1 a,,) 1-2 1 2OMPa 7-2 1 2OMPa 2-1 1 2OMPa 8-1 1 2OMPa 2-2 l2OMPa 8-2 I2OMPa 3-1 12OMPa 9-1 1IOMPa 3-2 12OMPa 9-2 12OMPa 4-1 1 2OMPa 10-1 12OMPa Specimen Nf Specimen Nr 1-1 1,636,480 7-1 310,080 1-2 794,530 7-2 508,100 2-1 608,390 8-1 308,400 0 50000 100000 150000 200000 250000 300000 350000 Number of cyde
Fig. 19 Stiffness curve for specimen 8
S-N data correlation
Summarizing the stress values presented in the previous sections, it was demonstrated that the structural stresses can be obtained in consistent manner. In this regard, this section presents the
S-N data obtained from the fatigue test. Fatigue test result with
final fracture life for each specimen is summarized in Table 5. le 5 Test result of fatigue life for each specimen
240 220 200 180 160 E 140
z
120 a 100 --80 60 40 20 oFig. 20 illustrates the fatigue life of each specimen in terms of nominal stress versus cycles to failure. It should be noted that nominal stress is calculated ignoring any bending induced
contributions to the overall stress concentrations at weld end due to the asymmetry of the specimen geometry. Therefore, the S-N
data appeared in flat.
en
Q-n
en C 61 o, en en C g oz
1000 loo-Io 10' 10' N, cyclesFig. 20 Nominal stress range versus failure cycles
Fig. 21 presents S-N curve presented using hot spot stress. Hot spot stress is calculated as explained in previous section. Since
the extrapolated hot spot stresses provide an indication of the stress concentration on the surface relatively close to the weld
end, bending effects
are captured in the hot spot stress
calculations. Thus, slightly improved correlation among the S-Ndata from the edge details can be seen. However, the overall
data scatter remains essentially the same as the case of nominal stresses. u 10' 10' 1000 en Q. n s) a' C
¡
100 10 1000 ca O-n en a, C a en en 100 at
C en ca 3-= a. w 10 #1-1 #1-2 £ #2.1 V #2-2 4 #3-1 #3-2 #4.1 #5-1 5 #6-1 * #6-2 0 #1-1 U 47-2 S#a.1AI&2y#6-14 #6.2#10-1C#10-2 #11-1 S #11-2 * #12-1 5 #12-2 - FAlSO 10' 10' N, cyclesFig. 21 Hot spot stress range based S-N data (20% loading)
Fig. 22 illustrates S-N plots using equivalent structural stress (ESS). Stress values for ESS are calculated based on the stress concentrations calculated in the case of 20% tensile loading according the methods explained in previous section. AIl data
essentially gathered into a single narrow band, as shown in Fig. 22. 10'
J
#1-1 #1-2 £ #2-1 V #2.2I
#4-2 #5-2 #6-1 5 #6-2 #8-1 * #8-2 #9-2 u #10-1 5 #10-2 A #12-1 V #12-2 - Master S-N jrve lo' 10' N, cyclesFig. 22 Equivalent structural stress range based S-N data (20% loading)
From the above discussion, it was demonstrated that structural
stress definition can be effectively applied to correlating fatigue
test data from various joint types, loading modes, and plate
thicknesses. The effectiveness of the equivalent structural stress
parameter has been presented by consolidating S-N data into a
single narrow band, and this clearly implies that improved
fatigue life prediction can be achieved.10' lo, 10' 2-2 737,150 - 8-2 297,020 3.-I 610,220 9-1 767,420 3-2 1,116,710 9-2 1,083,250 4-1 277,650 10-1 970,540 4-2 348,380 10-2 1,183,900 5-1 552,940 11-1 821,820 5-2 327,770 11-2 794,270 6-1 532,820 12-1 527,590 758,580 6-2 433,910 12-2
* All cracks occurred at weld toe
Paper No. Year - Last name of first author Page number
#1-1 #1-2 L #2-1 V #2-2 4 #3-1 #3-2 #4-1 C #4-2 S #5-1 * #5-2 #6-1 #6-2 #7-1 £ #7-2 y #6-1 4 #6-2 #6-1 #6-2 #10.1 S #10-2 * #11-1 5 #11-2 #12-1 #12-2 - FATtO
FATIGUE ASSESSMENT OF TYPICAL SHIP
STRUCTURES EMPLOYING STRUCTURAL
STRESS AND HOT SPOT STRESS APPROACH
As a later part of this study, a systematic investigation is carried
out for fatigue life assessment of side shell longitudinals on
8,100TEUcontainer vessel employing structural stress.
Fatigue ljfe assessment procedure of ship structures
Fatigue life assessment of welded joints in ship structures can be carried out using long term stress distribution and S-N curvas.
In the case of simplified fatigue analysis, fatigue strength is analyzed using loadings defined from classification societies, not using ship motion analysis. The fatigue damage ratio is finally estimated using Palmgren-Miner rule with long-term
stress range distribution. The long-term stress range distribution
is defined by the Weibull distribution. The fatigue life
is calculated employing Weibull distribution factors (scale andshape parameter) and relevant S-N curves.
Flow diagram over fatigue analysis procedures are shown in Fig.
23 applyiñg equivalent structural stress and notch stress using master S-N curve and DNV S-N curve. Load response in the
diagram includes the loadings from internal or external pressure
and hull girder wave bending moments. Using each equivalent structural stress and notch stress defined with respect to load
cases, combined stress ranges can be obtained and fatigue
damage ratio is calculated from long-term stress range distribution and the master SN curve and DNV S-N curve.JLoad response
Notch Stress (Equivalent Structural Stress)
I
Stress components
Combination of stresses (Stress range)
Long term stress distribution
4
Fatigue Damage Calculation
Hot spot stress (Structural Stress)
S-Ncurve (Master S-N curve)
Fig. 23 Flow diagram over fatigue analysis procedures
In the simplified method, dynamic loading may be divided into
global wave bending moments and local load such as external
pressure and internal pressure.
The following eight dynamic load cases have been applied to the
FE model and the load cases applied are listed in Table 6.
Boundary condition of the finite element model was applied as a simple support condition.Table 6. Load cases considered for fatigue calculation
Since global wave bending moments are based on vertical wave
bending moment and horizontal wave bending moment at
probability level of exceedance from lACS, they are modified to
10 probability level of exceedance to be compatible with
pressure loading components defined at l0 probability level. Usiñg correlation factor (p) which considers phase difference for
combination of vertical and horizontal wave load, global
combined stress range(Mg) is finally defined by Eq. (27).2Jo-h + wl+ °g1 +
(27)
+
2Pvhvh
whereEwg combined grobal stress range
= range of stress due to wave induced vertical hull girder
bending moment (o =1/2 ¿sa,,)
=range of stress due to wave induced horizontal hull girder bending moment (0h=1/2Mh)
=warping stress due to torsion at position considered bending stress
of deck structure due to
torsionaldeformation of hatch(0)
Pvh = 0.10, average correlation between vertical and horizontal
wave induced bending stress
External pressure is determined compariñg dynamic pressures
from ship rolling motion and ship pitching motion, whichever is higher. The internal pressure is determined from the acceleration
of liquid cargo or ballast water among three directions and
selected from whichever is the highest.
Local combined stress range (M,) is composed of external and internal pressures with a correlation factor expressed in Eq. (28).
Local combined stress range
is divided into full loaded condition and ballast condition.Loading type Loading condition LCI Vertical wave bending
moment Fully loaded / Ballast LC2 Horizontal wave bendingmoment Fully loaded LC3
-Horizontal wave bending
- moment
Ballast
LC4 Torsional moment Fully loaded
LC5 Torsional moment Ballast
LC6 External pressure Fully loaded
LC7 External pressure Ballast
LC8 Internal pressure Ballast
Ao, =
Jcr +c +2poo
(28) where 10-,= combined local stress range
=amplitude of stress due to the dynamic external sea pressure loads (tension=positive)
= amplitude of stress due to the dynamic internal pressure
loads (tension=positive)
AOg =max
Pp=average correlation between sea pressure loads and internal
pressure loads
i
z +k
+ IyIxH
2
iO.T,
4-L
4-B
5.L-T,
where L is rule length of ship in meter and T, is actual draft. B is the greatest moulded breadth of the ship andx,y, x are the
longitudinal, transverse and vertical distance from the origin (at midship, centerline, baseline) to the load point of the considered structural detail.
If a combined long term stress response analysis is not carried out, the combined stress range response from the combined global stress and local stress range responses is the largest of
(Hovem 1993):
IO.6L\cr +\o
&7o=fefmma
LOg +O.6-ia,gwhere f, is the operation route reduction factor and fm is the
mean stress reduction factor(JÇ,,=0.85 maybe applied on the long term stress distribution). A reduction in the effective estimated stress response is achieved for vessels that for longer periods
operate in environments not as harsh as the North Atlantic. For world wide trade, the reduction factor may be taken as 0.8. When the long-term stress range distribution is defined applying
Wóibull distributions for the different load conditions, and a one-slope S-N curve is used, the fatigue damage is given by
(DNV 2003),
T N,
D=
p,,q"T(l
!)
17
where, D=accumulated fatigue damage
a, m =S-N fatigue parameters
N, =total number load conditions considered p,,=fractiOn of design life in load condition n
Ta=design life of ship in seconds
= Weibull stress range shape distribution parameter for load conditionn
qn = Weibull stress range scale distribution parameter for load
coñditionn
V0 =long-term average response zero-crossing frequency
77=usage factor. Accepted usage factor is defined as 77 =1.0
F(1+-r-) =gamma function
The Weibull scale parameter is defined from the stress range
level, as
&70 q
- (lnno)1Th
(31)
Paper No. Year - Last name of first author
where,n0is the number of cycles over the time period for which
the stress level is defined.
Target structure and fatigue crack definition
In this study, typical fatigue crack points are assumed in the
vicinity of intersection of side longitudinals and transverse web
frame for a 8,100 TEU class container carrier.
Principaldimension of container vessel is listed in Table 7 and finite
element model for full ship is shown in Fig. 24.
Fig. 24 Finite element model of target vessel Table 7. Principal dimension of target vessel
FE analysis is carried out for full ship and structural stresses as well as hot spot stresses are calculated in critical details of side longitudinals located between design draft (TF) and ballast draft
(TB). Fig. 25 shows the concerned section of web frame and
local area in finite element model, and Table 8 lists the design
details.
Table 8. Geometry of stiffener considered
Page number
Length of ship 305.356m
Breadth of ship 42.8m
Depth of ship 246m
Draft, Fully loaded 14.47m
Draft, Ballast loaded 7.42m
Max. Speed 26.4knoi
Distance above keel 8.176m
Stiffener spacing 868rnm
Height of stiffener 300mm
Thickness of web 11mm
Width offlange 90mm
u.
IPUPlIpIupIgpp
-
U!uI.iupuii.11,1.
-L!IUIIIIIL..III
i
I
LUUIp
U Iii
U iii
U1I1
11111111111 III
ir
".jI
iu,ip
1111
Fig. 25 Section of midship in finite element model
Three possible crack points slot detail is defined as shown in Fig.
26. For each HS (Hot Spot) point, semi-elliptical cracks are
anticipated at HS 1 and HS 2 on the longitudinal face plate and collar plate, whereas edge cracks are expected at HS 3.
Fig. 26 Configuration of longitudinal connection and definition of fatigue crack points
FE models used in the fatigue strength assessment are classified
into 4 groups as shown in Figs. 27, 28, 29 and 30: 1 .Ot xl .Ot, 2.01 x 2.0t, 2.Ot x 2.Ot(paver) and 3.Ot x 3.01 meshes for the parametric studies to veri1,' mesh-insensitivity. Fatigue lives were calculated employing structural stress approach on every mesh size and shape which are mentioned above. In order to
compare with hot spot stress approach, mesh of i .Ot x 1.01 was calculated by using hot spot stress.
Fig. 27 Finite element model of local detail (1 .Ot xl .01)
"u
ii
Fig. 29 Finite element model of local detail (2.Ot x 2.Ot Paver)
Fig. 30 Finite element model of local detail (3.01 x 3.01)
FATIGUE ASSESSMENT RESULTS
For the design life of 20 years, fatigue damage ratio has been calculated with the equivalent structural stress (ESS) and the design master S-N curve. In order to compare with the fatigue lives from the hot spot stress (HSS) approach, the S-N curve
from DNV Classification Note No. 30.7 was employed. Hot spot stress approach is applied to the FE model of which mesh size is
1.Otx 1.01.
Parameters for the use of design master S-N curve and DNV
curve are as given in Table 9. Palmgren-Miner rule was used to calculate damage ratio.
Table 9. S-N narameters
Figs. 31, 32, and 33 show fatigue lives at HSI, HS2 and HS3, respectively. Each fatigue lives are normalized by calculated
fatigue life employing hot spot stress method.
IA 1.2 1.0 _i 0.8
6
0.4 0.2 0.0Fig. 31 Result of fatigue life at HS I
1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0
Fig. 32 Result of fatigue life at HS2
logN = logamlogo
loga m
Design master S-N curve (SS) 13.33 3.08
DNV curve (HSS) 12.76 3.0
1.4 1.2 1.0 a) 'I-0.8 0.6 0.4 02 0.0
Fig. 33 Result of fatigue life at HS3
Comparing with the results of 2 methods from 1.0: x 1.0: meshed model, the fatigue lives from structural stress
and hot spot stress give only a small difference. In considering
mesh shape insensitivity, result of fatigue lives from 2.0: x 2.0:
and 2.Ot x 2.0: paver have good correlation, when structural
stress is used.
in the case of HS1, the calculated fatigue life using structural
stress approach from I .0, x I .Ot meshed model is approximately
10% less than larger meshed model. On the other hand, in the
case of HS2 and HS3, the calculated fatigue
lives usingstructural stress
approach from I.Otxl.Or are more than
maximum 30% lager meshed models.
In case of HS2, however, the calculated fatigue life using
structural stress approach from 3.Ot x 3.0: meshed model isapproximately 30% less than those from the 1.0: x 1.0: one. It is
considered that 3.0: x 3.0: meshed model is failed to represent
its own geometrical condition in the vicinity of concerned area.
CONCLUSIONS
In this study experimental structural stress measurement techniques are investigated. The effectiveness of structural stress method is compared with
that of hot
spot stress. Themeasurement techniques are based on a series of strain gauge pairs placed on both sides of a specimen width to resolve both membrane and bending stress
components. And also the
parametric studies for mesh size and shape insensitivity of
structural stresshave been
carried out. Fatigue strengthassessment of side shell longitudinal stiffener of 8,100 lEU container vessel is performed. From this research following
conclusions are drawn.
Consistent structural stress values can be obtained experimentally using stress measurements in proper distance. Stress values obtained using linear regression are
used to calculate
structural stressesto minimize the
fluctuation from experiments.Both hot spot stress and structural stress can be successfully obtained from the experiment. Structural stress
values calculated
based on the
linear regression ofmeasured stresses result in lower stress value than those of hot spot stress.
Hot spot stress vs. life shows a reasonable consolidation
between similar types of edge detail specimens. However,
hot spot stress vs. life cannot show further consolidation
with those of different types/thickness of specimens. Equivalent structural stress with thickness correction versus life shows a fairly good consolidation between edge detail test results considered in this study.
A consistent structural stress approach is employed for the
fatigue strength assessment of side
shell longitudinalstiffeners of an 8,100 TEU container vessel. The similar
fatigue life results are compared with that of hot spot stress approach.
In case of structural stress approach, the stress values from
finite element analysis for 2.Ot model are
in general applicable to fatigue strength assessment. In consideringmesh shape insensitivity, result from different mesh shape
models gives good correlation. From this result,
it isconfirmed that modeling time associated with local fatigue
model can be significantly reduced by using larger and
irregular mesh types.
For fatigue strength assessment of ships, structural stress approach is found to be a viable alternative as employing
the mesh size insensitive characteristics.
ACKNOWLEDGEMENTS
This research is sponsored by Advanced Ship Engineering
Center of Korea Science & Engineering foundation. The
financial support is gratefully acknowledged.REFERENCES
Battelle Structural Stress uP Report (NO. N004431-01): Mesh-Insensitive Structural Stress Met hodfor Fatigue Evaluation of
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C. Guedes Soares and Y. Garbatov, "Reliability based fatigue design of maintained welded joints in the side shell of tankers", The 3td International Symposium on Fatigue Design, Editors: G. Marquis and J. Sohn, European Structural Integrity Society (ESIS), pp. 13-28, 1998
Cui, W. A state of the art review on fatigue ¡(fe prediction methods for metal structures. Journal of Marine Science and Technology, 2002, 7, 43-56.
Det Norske Ventas, Fatigue assessment of ship structure, Classification Notes No. 30.7, 2003
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