FE calculations for the welds and bolts June

FE calculations for the welds and bolts June 1 st 2015 Norbert Kuder

Welds Contacts established after the bolt preload to prevent the weld prestressing. 2. 5 3. 3 3. 2 3. 1 2. 4 2. 3 10. 4 3. 4 2. 1 3. 5 3. 6 10. 4 10. 3 1. 4 4. 1 4. 2 1. 2 4. 3 1. 5 before preload 1. 6 10. 4 1. 3 1. 1 10. 2 4. 4 10. 3 direction of relative plate movement 2. 2 10. 3 4. 5 10. 1 9. 4 6. 5 10. 2 9. 3 10. 2 6. 4 7. 1 6. 3 7. 2 6. 2 7. 3 7. 4 10. 1 6. 1 7. 5 7. 6 9. 2 5. 4 8. 1 8. 2 9. 1 8. 3 8. 4 5. 2 5. 5 5. 6 10. 1 edg e 5. 3 5. 1 8. 5 face

Welds My Z Y Fy Mz Fz X Fx Mx Coordinate systems created for every single weld and the forces and moments extracted from ANYS.

Welds a y z z Pressure + pretuning y x L throat section AT = L∙a I = L 3 a/12 Results compared for the weld 2. 3 Stress [MPa] Analytical* FE 20. 30 20. 32 30. 42 30. 5 3. 59 6. 76 6. 77 ? 10. 83 Based on several configuration of moments and forces, the torsional stress was extracted from ANSYS and expressed as: *according to EN 1993 -1 -8 : 2005 (E)

Good correspondance of the analytical calculations and the FE results. Weld Fx [N] Fy [N] Fz [N] My [Nmm] Mz [Nmm] 9. 4 330. 76 -646. 84 883. 45 39647 -33350 61. 8 10. 4 -231. 28 -911. 65 687. 33 -39281 34881 59. 8 Welds

• • Welds For the rest welds the stress is 15 – 30 MPa. The results for the frictional contacts is better by 10% for them. The welds on the sides are loaded the same for the frictional and frictionless model. The stress is acceptable, however there is a way to decrease the load on the side welds. . . ~80 MPa ~70 MPa

Bolts 2 Bolts 3 Bolts 11 Bolts 12 Bolts 4 Bolts 10 Bolts 6 Bolts 7 Bolts 9 Bolts 5 Bolts 8

Frictionless Frictional Bolts Max bending moment Max shear force Max axial force Equivalent stress [MPa] Safety coefficient 1 1495. 4 222. 77 3858 639. 77 1. 30 1. 50 2 1158. 6 166. 08 3854. 2 580. 17 1. 43 1. 57 3 1647. 8 245. 38 3870. 8 667. 83 1. 24 1. 46 4 1042. 4 149. 38 3848. 3 559. 16 1. 48 1. 63 5 1157. 7 173. 04 3840. 5 578. 67 1. 43 1. 65 6 1385 207. 61 3825. 8 617. 21 1. 34 1. 58 7 1363. 4 203. 86 3844. 3 615. 22 1. 35 1. 57 8 1114. 9 166. 62 3822. 8 569. 42 1. 46 1. 67 9 153. 75 22. 62 3930. 5 410. 88 2. 02 10 144. 21 19. 79 3954. 3 411. 53 2. 02 11 176. 69 24. 66 3935. 9 415. 44 2. 00 2. 03 12 137. 91 20. 65 3937. 5 408. 78 2. 03 Bolts do not bend! Bolts Smaller bending and shear

Bolts Mw 2 Fs Fi = p∙Ai Rw 2 Mb

Bolts Original design Overlapped sides Bolts loaded about 10 times more (moment and shear force), 75% smaller total shear force and 25% smaller total moment for the side weld close to the pick-up