Suurlujuusteräksisen ruuviliitoksen fretting-väsyminen

Tässä kandidaatintyössä selvitetään suurlujuusteräksestä S960 valmistetun ruuviliitoksen alttiutta fretting-väsymiselle. Fretting on ilmiö, jossa syklinen ulkoinen kuorma aiheuttaa tiukasti puristuksissa olevien kontaktipintojen välille pientä suhteellista mikroliikettä. Fretting-väsymisessä mikroliike ja kontaktijännitykset aiheuttavat rakenteeseen särön muodostumisen. Tutkimuksessa käytettiin menetelmätriangulaatiota ja tutkimusmenetelmiksi valittiin kirjallisuusselvitys, FE-laskenta ja laboratoriokoe. Tutkimuksissa havaittiin, että matalalujuusteräksinen ruuviliitos kestää fretting-väsymistä erinomaisesti, kun taas suurlujuusteräksen kestävyys on huomattavasti heikompi. Tutkimuksessa havaittiin myös, että ruuviliitos aiheuttaa kontaktipintojen erkanemista, mikä muuttaa kontaktijännitysjakaumaa. Myös materiaalin kitkakertoimella on suuri merkitys rakenteen kontaktijännitysjakaumaan etenkin ruuvin reiän läheisyydessä.

Distortion and internal warping torsion of a double symmetric hollow section

This thesis is made in cooperation with Laboratory of Steel Structures and the steel company SSAB. Maximization of the benefits of high-strength steel usually requires the usage of thin wall thicknesses. This means the failures related to buckling, distortion and warping stand out. One must be aware of these phenomena to design thin-walled structures stressed with forces such as torsional loading. It is also important to take into account small stress ranges when evaluating the accurate fatigue strength of structures. The objective of this thesis is to clarify the theory of the uniform and non-uniform torsion. This paper focuses on warping due to the non-uniform torsion in double symmetric box girder and structural hollow section. The arisen stress states are explained and researched using the finite element method. Another research target is the distortion in double symmetric box girder due to torsion, and the restraining effect of transverse diaphragms at the load end. Multiple transverse diaphragms are used to study more efficient restraining against warping and distortion than a common one end plate structure.

Lujien terästen laserhitsaus

Työn tavoitteena oli tarkastella lujien terästen laserhitsausta ja pohtia niiden yhteiskäytön mahdollisuuksia tulevaisuudessa. Tarkoituksena oli selvittää, miten nykyiset laserhitsauslaitteistot soveltuvat lujien terästen hitsaukseen ja mitä hyötyjä laserhitsauksella saavutetaan verrattuna perinteisimpiin hitsausmenetelmiiin.

Stresses of a boat trailer

In this thesis work, a strength analysis is made for a boat trailer. The studied trailer structure is manufactured from Ruukki’s structural steel S420. The main focus in this work is in the trailer’s frame. The investigation process consists two main stages. These stages are strain gage measurements and finite elements analysis. Strain gage measurements were performed to the current boat trailer in February 2015. Static durability and fatigue life of the trailer are analyzed with finite element analysis and with two different materials. These materials are the current trailer material Ruukki’s structural steel S420 and new option material high strength precision tube Form 800. The main target by using high strength steel in a trailer is weight reduction. The applied fatigue analysis methods are effective notch stress and structural hot spot stress approaches. The target of these strength analyses is to determine if it is reasonable to change the trailer material to high strength steel. The static strengths of the S420 and Form 800 trailers is sufficient. The fatigue strength of the Form 800 trailer is considerably lower than the fatigue strength of the S420 trailer. For future research, the effect of hot dip galvanization to the high strength steel has to be investigated. The effect of hot dip galvanization to the trailer is investigated by laboratory tests that are not included in this thesis.

Teleskooppipuomin valmistuksen kehittäminen

KESLA 2110T -autonosturin siirtopuomin teleskooppimainen rakenne koostuu kolmesta sisäkkäin menevästä puomista. Näiden puomien muodonmuutokset ja mittavaihtelut ovat kriittisiä seikkoja siirtopuomin kokoonpantavuuden kannalta. Liian suuret muodonmuutokset ja mittavaihtelut aiheuttavat ylimääräistä työtä siirtopuomien kokoonpanossa, mikä lisää tuotteen läpimenoaikaa ja valmistuskustannuksia. Työssä pyrittiin selvittämään valmistusprosessin kriittisimmät osat kokoonpantavuuden kannalta sekä varmistamaan niiden vaikutus mittauksin. Valmistusprosessin ongelmakohtia selvitettiin ensin haastattelemalla tuotannon työntekijöitä ja toimihenkilöitä. Saatujen tuloksien perusteella suunniteltiin tarkoituksenmukaiset mittausjärjestelyt, joilla valmistusprosessin ongelmakohdat voidaan todeta. Mittaukset suoritettiin kahdelle viiden siirtopuomin koesarjalle ja samalla kehitettiin valmistusprosessia. Puomien mittauksissa keskityttiin kokoonpanon kannalta kriittisiin mittoihin. Mittatuloksia arvioidaan toleranssien, standardien ja prosessien suorituskyvyn parametrien avulla. Työssä selvitettiin myös rullamuovauksen soveltuvuutta puomien valmistusmenetelmäksi sekä välyksen vaikutusta kokoonpantavuuden kehittämiseksi. Mittauksissa havaittiin mittavirheiden kertautuvan valmistusprosessin varrella. Kokoonpantavuuden kannalta kriittisimmät virheet ovat puomien alakotelon V-pohjan toislaitaisuus sekä puomien kieroutuminen hitsausvaiheessa. Puomien korkeus- tai leveysvaihteluilla ei ole suurta merkitystä, sillä niitä voidaan kompensoida liukupaloja säätämällä.

Ultralujan teräksen kaarijuotto

Tässä diplomityössä tutkitaan ultralujan rakenneteräksen kaarijuotolla valmistettujen liitosten väsymiskestävyyttä. Tutkittavat liitokset ovat kuormaa kantamattomia X-liitoksia. Tutkinnassa vertaillaan puhtaasti juottamalla valmistettua liitosta hitsauksen ja juoton kombinaatioliitokseen, jossa pohjapalkona toimivan hitsin rajaviivalle on juotettu lisäpalko. Kaarijuottoa esitellään yleisesti liittämismenetelmänä. Ultralujaa rakenneterästä esitellään yleisesti ja tarkastellaan sen metallurgista käyttäytymistä sekä juotettaessa, että hitsattaessa. Tutkimuksessa tehtiin kaikkiaan 21 väsytystestiä. Väsytystestit muodostuivat kolmesta eri koekappalesarjasta. Ensimmäisen ja toisen sarjan koekappaleet tehtiin juottamalla, eri lisäaineilla. 3. sarjassa pienat hitsattiin, jonka jälkeen hitsin rajaviivalle tehtiin juotto. Kappaleiden geometriat mitattiin ennen testejä, ja osasta kappaleista mitattiin jäännösjännitykset. Kappaleista otettiin hieitä, joista tehtiin kovuusmittaukset ja suoritettiin makro- ja mikrotason tarkastelua liitosprosessin lämmöntuonnin vaikutuksesta. Väsytyskokeiden perusteella kappaleille määritettiin nimelliset ja rakenteelliset väsymisluokat. Tuloksista piirrettiin S-N –käyrät. Liitoksista tehtiin FEA-mallit, joista määritettiin liitoksen rajaviivalle muodostuva jännitys ja 2. sarjan koekappaleiden laskennalliset kestoiät. 1. sarjan juotoksissa oli ongelmana juotoksen tarttuvuus teräksen pintaan. 2. sarjan koetulokset olivat kaikkein parhaita. 3. sarjan kombinaatioliitokset ylsivät kohtalaisiin väsymisluokkiin. 2. sarjan koetulosten perusteella kaarijuotossa on potentiaalia ultralujan rakenneteräksen liittämismenetelmänä. Jatkotutkimuksen tarve on kuitenkin laaja. Tämä työ osoitti, että kaarijuottaminen voi olla vaativa liittämisprosessi, sillä toimiakseen se vaatii varsin tarkat parametrit, ja lisäksi prosessi on melko herkkä olosuhdemuutoksille.

Protection of the high-voltage equipment with reduced insulation strength

Power transformer is the most expensive equipment on a substation. It is always necessary to get needed benefit with the lowest expenses. Producing of power transformers with reduced insulation strength is one of the possible ways to reduce expenses. Exploitation of such transformers was begun in the end of 70-th in the last century. Protection from overvoltages was done with valve-type magnetic combined surge arresters with increased blanking voltage during switching overvoltages. Nowadays there is the necessity of replacement of those devices. That’s why modernized nonlinear surge arrester was invented. This master’s thesis is focused on the use research of that modernized device in comparison with usual nonlinear surge arresters. The goal is to show the lightning overvoltages level using different types of nonlinear surge arresters and then calculations of the lightning protection reliability.

On the effects of welding parameters on weld quality of plasma arc keyhole welding of structural steels

The possibility and the usefulness of applying plasma keyhole welding to structural steels with different compositions and material thicknesses, and in various welding positions has been examinated. Single pass butt welding with I groove in flat, horizontal vertical and vertical positions and root welding with V , Y and U grooves of thick plate material in flat position have been studied and the welds with high quality has been obtained. The technological conditions for successful welding are presented. The single and interactive effects of welding parameters on weld quality, especially on surface weld defects, geometrical form errors, internal defects and mechanical properties (strength, ductility, impact toughness, hardness and bendability) of weld joint, are presented. Welding parameter combinations providing the best quality welds are also presented.

Defining the keyhole modes – the effects on the weld geometry and the molten pool behaviour in high power laser welding of stainless steels

Keyhole welding, meaning that the laser beam forms a vapour cavity inside the steel, is one of the two types of laser welding processes and currently it is used in few industrial applications. Modern high power solid state lasers are becoming more used generally, but not all process fundamentals and phenomena of the process are well known and understanding of these helps to improve quality of final products. This study concentrates on the process fundamentals and the behaviour of the keyhole welding process by the means of real time high speed x-ray videography. One of the problem areas in laser welding has been mixing of the filler wire into the weld; the phenomena are explained and also one possible solution for this problem is presented in this study. The argument of this thesis is that the keyhole laser welding process has three keyhole modes that behave differently. These modes are trap, cylinder and kaleidoscope. Two of these have sub-modes, in which the keyhole behaves similarly but the molten pool changes behaviour and geometry of the resulting weld is different. X-ray videography was used to visualize the actual keyhole side view profile during the welding process. Several methods were applied to analyse and compile high speed x-ray video data to achieve a clearer image of the keyhole side view. Averaging was used to measure the keyhole side view outline, which was used to reconstruct a 3D-model of the actual keyhole. This 3D-model was taken as basis for calculation of the vapour volume inside of the keyhole for each laser parameter combination and joint geometry. Four different joint geometries were tested, partial penetration bead on plate and I-butt joint and full penetration bead on plate and I-butt joint. The comparison was performed with selected pairs and also compared all combinations together.

A novel approachfor assessing the fatigue strength of ultrasonic impact treated welded structures.

It is commonly observed that complex fabricated structures subject tofatigue loading fail at the welded joints. Some problems can be corrected by proper detail design but fatigue performance can also be improved using post-weld improvement methods. In general, improvement methods can be divided into two main groups: weld geometry modification methods and residual stress modification methods. The former remove weld toe defects and/or reduce the stress concentrationwhile the latter introduce compressive stress fields in the area where fatigue cracks are likely to initiate. Ultrasonic impact treatment (UIT) is a novel post-weld treatment method that influences both the residual stress distribution andimproves the local geometry of the weld. The structural fatigue strength of non-load carrying attachments in the as-welded condition has been experimentally compared to the structural fatigue strength of ultrasonic impact treated welds. Longitudinal attachment specimens made of two thicknesses of steel S355 J0 have been tested for determining the efficiency of ultrasonic impacttreatment. Treated welds were found to have about 50% greater structural fatigue strength, when the slope of the S-N-curve is three. High mean stress fatigue testing based on the Ohta-method decreased the degree of weld improvement only 19%. This indicated that the method could be also applied for large fabricated structures operating under high reactive residual stresses equilibrated within the volume of the structure. The thickness of specimens has no significant effect tothe structural fatigue strength. The fatigue class difference between 5 mm and 8 mm specimen was only 8%. It was hypothesized that the UIT method added a significant crack initiation period to the total fatigue life of the welded joints. Crack initiation life was estimated by a local strain approach. Material parameters were defined using a modified Uniform Material Law developed in Germany. Finite element analysis and X-ray diffraction were used to define, respectively, the stress concentration and mean stress. The theoretical fatigue life was found to have good accuracy comparing to experimental fatigue tests.The predictive behaviour of the local strain approach combined with the uniformmaterial law was excellent for the joint types and conditions studied in this work.

The high-speed induction motor: calculating the effects of solid-rotor material on machine characteristics

A method for the analysis of high-speed solid-rotor induction motors in presented. The analysis is based on a new combination of the three dimensional linear method and the transfer matrix method. Both saturation and finite length effects are taken into account. The active region of the solid rotor is divided into saturated and unsaturated parts. The time dependence is assumed to be sinusoidal and phasor quantities are used in the solution. The method is applied to the calculation of smooth solid rotors manufactured of different materials. Six rotor materials are tested: three construction steels, pure iron, a cobaltiron alloy and an aluminium alloy. The results obtained by the method agree fairly well with the measurement quantities.

Natural and synthetic fibres improving tensile strength and elongation of paper products

The theory part of the Master’s thesis introduces fibres with high tensile strength and elongation used in the production of paper or board. Strong speciality papers are made of bleached softwood long fibre pulp. The aim of the thesis is to find new fibres suitable for paper making to increase either tensile strength, elongation or both properties. The study introduces how fibres bond and what kind of fibres give the strongest bonds into fibre matrix. The fibres that are used the in manufacturing of non-wovens are long and elastic. They are longer than softwood cellulose fibres. The end applications of non-wovens and speciality papers are often the same, for instance, wet napkins or filter media. The study finds out which fibres are used in non-wovens and whether the same fibres could be added to cellulose pulp as armature fibres, what it would require for these fibres to be blended in cellulose, how they would bind with cellulose and whether some binding agents or thermal bonding, such as hot calendaring would be necessary. The following fibres are presented: viscose, polyester, nylon, polyethylene, polypropylene and bicomponent fibres. In the empiric part of the study the most suitable new fibres are selected for making hand sheets in laboratory. Test fibres are blended with long fibre cellulose. The test fibres are viscose (Tencel), polypropylene and polyethylene. Based on the technical values measured in the sheets, the study proposes how to continue trials on paper machine with viscose, polyester, bicomponent and polypropylene fibres.

Improvement of Surface Strength of Paper

Offset printing is a popular printing method that is especially suitable for large and fast print jobs. Newspapers, magazines and books are typical examples of products printed with offset method. In high volume printing production high efficiency is essential. Offset printing uses tacky inks that cause serious stress to the paper surface. Dusting and linting are terms that describe how loose and weakly bonded particles are removed from the paper surface in the printing process. The removed particles accumulate in the process causing deteriorating print quality. This forces the printing operators to stop production for washing and cleaning. Time and money are lost. Dusting and linting tendency of paper can be decreased by improving the surface strength of paper. In the present work a method to increase the surface strength of paper was studied. In the literature part offset printing method and challenges related to offset printing are presented. A review of new methods for surface sizing of paper is also presented. The experimental part presents trials where an apparatus for improving paper surface strength was tested and developed in mill scale. Laboratory work supporting the actual mill scale operations is also presented. The acquired results provide a solid base of information to make decisions on how to proceed with research in the present field of study.