Vibration based damage identification of a scale-model steel frame structure subjected to bolt connection failures

Large-span steel frame structures prove to be an ideal choice for their speed of construction, relatively low cost, strength, durability and structural design flexibility. For this type of structure, the beam-column connections are critical for its structural integrity and overall stability. This is because a steel frame generally fails first at its connectors, due to the change in stress redistribution with adjacent members and material related failures, caused by various factors such as fire, seismic activity or material deterioration. Since particular attention is required at a steel frame’s connection points, this study explores the applicability of a comprehensive structural health monitoring (SHM) method to identify early damage and prolong the lifespan of connection points of steel frames. An impact hammer test was performed on a scale-model steel frame structure, recording its dynamic response to the hammer strike via an accelerometer. The testing procedure included an intact scenario and two damage scenarios by unfastening four bolt connections in an accumulating order. Based entirely on time-domain experimental data for its calibration, an Auto Regressive Average Exogenous (ARMAX) model is used to create a simple and accurate model for vibration simulation. The calibrated ARMAX model is then used to identify various bolt-connection related damage scenarios via R² value. The findings in this study suggest that the proposed time-domain approach is capable of identifying structural damage in a parsimonious manner and can be used as a quick or initial solution.

Structural damage identification based on self-fitting ARMAX model and multi-sensor data fusion

Statistical time series methods have proven to be a promising technique in structural health monitoring, since it provides a direct form of data analysis and eliminates the requirement for domain transformation. Latest research in structural health monitoring presents a number of statistical models that have been successfully used to construct quantified models of vibration response signals. Although a majority of these studies present viable results, the aspects of practical implementation, statistical model construction and decision-making procedures are often vaguely defined or omitted from presented work. In this article, a comprehensive methodology is developed, which essentially utilizes an auto-regressive moving average with exogenous input model to create quantified model estimates of experimentally acquired response signals. An iterative self-fitting algorithm is proposed to construct and fit the auto-regressive moving average with exogenous input model, which is capable of integrally finding an optimum set of auto-regressive moving average with exogenous input model parameters. After creating a dataset of quantified response signals, an unlabelled response signal can be identified according to a 'closest-fit' available in the dataset. A unique averaging method is proposed and implemented for multi-sensor data fusion to decrease the margin of error with sensors, thus increasing the reliability of global damage identification. To demonstrate the effectiveness of the developed methodology, a steel frame structure subjected to various bolt-connection damage scenarios is tested. Damage identification results from the experimental study suggest that the proposed methodology can be employed as an efficient and functional damage identification tool. © The Author(s) 2014.

Experimental stress analysis of a steel light truck wheel

The development of a new automotive wheel requires extensive testing and possible design changes. The wheel investigated had three major changes during development. These three designs were subjected to a stress analysis, by experimental methods, to allow a comparison to be made between each design. The experimental program tested the wheels under conditions designed to simulate the loading of the front wheels whilst cornering. A loading frame was built for this purpose and all testing was performed statically by multiple loading for different directions of bending moment. Brittle lacquer coatings were used on each wheel to highlight high strain areas and indicate optimum locations for the placement of strain gauges. The strain gauges were then used to evaluate the strains. Wheel stud loads were also monitored via strain gauges applied to two of the wheel studs. All data was stored on magnetic tapes and the stress analysis performed by means of a minicomputer. The results of the stress analysis showed quantitatively the improvement in design from the first to the third wheel design. The analysis of the stud loads and their variation during loading indicated the optimum wheel mounting face geometry to ensure nut loosening would not occur in service.

Development of the sheared edge in the trimming of steel and light metal sheet, part 1 - experimental observations

Trimming experiments were conducted on sheet metals including two drawing steels, an aluminum alloy and a magnesium alloy, using a specially designed die in a mechanical press. The punch-die clearance was varied and data obtained on the rollover and burr height as a function of the clearance. Samples were also partially trimmed to examine crack initiation, the generation of the fracture surface profile and mechanism of burr formation. The results showed that while the burr height and rollover depth generally increased with increasing clearance for all examined materials, there were differences in the fracture surface profile shape, the burr shape, and the mechanism of burr formation, between the two steels and the two light alloys. The major cause of these differences appeared to be the rate of crack propagation through the sheet material.

Development of the sheared edge in the trimming of steel and light metal sheet, part 2 - mechanisms and modelling

The shearing behavior of a drawing-steel and aluminum alloy were investigated using hardness contours of partially deformed samples and a finite element model of the trimming process. Results showed that the stress and strain distributions within the work-piece were more strongly dependent on the punch penetration than the material properties of the work-piece. Differences in the final fracture surface profile and burr formation of the drawing-steel and aluminum alloy were a consequence of the shape of the stress and strain distribution when the crack in the sample became unstable, not when it was initiated. Results and existing literature suggest that a correlation may exist between the strain-rate sensitivity of the work-piece material and the burr mechanism and fracture surface profile of the trimmed part.

The mechanical characterization of low work hardening, high strength steel

One of the major challenges in assessing the mechanical properties of recovery annealed steel is the strain localization that occurs almost immediately on the formation of the first Lüders band, such that no or limited propagation of the Lüders band occurs along the tensile coupon. The stress raiser associated with the geometry of the standard tensile coupon means that this plastic deformation is often completely outside the standard extensometers on the coupon. Hence, no strain is measured during the test. While this is not important for assessing the tensile strength of the steel, it does mean that the strain related properties, such as the elastic limit of the steel, cannot be measured using standard testing techniques.This work addresses this issue by examining three techniques for ensuring that the strain occurs inside the extensometer. It is shown that the best technique is the extended extensometer, where the gauge length covers slightly more than the tensile coupon parallel length. While this leads to some variation in the width of the material being measured, compensation can be be made by adjusting the strain to correct the Young's Modulus.This technique has direct implications not just for recovery annealed steels, but for other high strength, low work hardening materials such as ultrafine ferrite. A particular requirement of these high strength steels in structural applications is a high elastic limit; hence, measurement of the strain related properties for these high strength materials must be considered vital in their mechanical assessment.

The production of ultrafine ferrite during hot torsion testing of a 0.11 Wt Pct C steel

Ultrafine ferrite grain sizes were produced in a 0.11C-1.6Mn-0.2Si steel by torsion testing isothermally at 675 °C after air cooling from 1250 °C. The ferrite was observed to form intragranularly beyond a von Mises equivalent tensile strain of approximately 0.7 to 0.8 and the number fraction of intragranular ferrite grains continued to increase as the strain level increased. Ferrite nucleated to form parallel and closely spaced linear arrays or “rafts” of many discrete ultrafine ferrite grains. It is shown that ferrite nucleates during deformation on defects developed within the austenite parallel to the macroscopic shear direction (i.e., dynamic strain-induced transformation). A model austenitic Ni-30Fe alloy was used to study the substructure developed in the austenite under similar test conditions as that used to induce intragranular ferrite in the steel. It is shown that the most prevalent features developed during testing are microbands. It is proposed that high-energy jogged regions surrounding intersecting microbands provide potential sites for ferrite nucleation at lower strains, while at higher strains, the walls of the microbands may also act as nucleation sites.

Experimental and numerical investigation of low pressure tube hydroforming on 409 stainless steel

Tube hydroforming has been widely used to produce automotive structural components due to the superior properties of the hydroformed parts in terms of their light weight and structural rigidity. Compared to the traditional manufacturing process for a closed-section member including stamping and followed by welding, tube-hydro forming leads to cost savings due to reduced tooling and material handling. However, the high pressure pumps and high tonnage press required in hydroforming, lead to increased capital investment reducing the cost benefits. This study explores low pressure tube hydro forming which reduces the internal fluid pressure and die closing force required to produce the hydroformed part. The experimental and numerical analysis was for low pressure hydro formed stainless steel tubes. Die filling conditions and thickness distributions are measured and critically analysed.

Effect of roller leveling on the bending behaviour of aged steel strip

The common grades of steel used in roll forming are: hot rolled carbon steel, high strength low alloy and recovery annealed cold rolled sheet. These steels are prone to ageing and are often skin passed and/or roller leveled to eliminate ageing as it can lead to problems in forming. In roll forming, shape defects such as bow, twist and camber are considered to be related to very small plastic strains in the longitudinal direction and hence knowledge of the material properties in the elastic plastic transition range is necessary if the process is to be modelled accurately. Previous studies with aluminium have indicated that skin pass rolling can lead to residual stresses in the strip. In this work, the study was extended to aged carbon steel and to the effect of roller leveling on both aged material and strip that had been given a light cold rolling to simulate a skin pass treatment. The results suggest that roller leveling reduced the magnitude of residual stresses resulting from skin pass rolling.

The significant differences observed between tensile and bending test results, at and near, the elastic plastic transition reinforces the need to consider bending properties when assessing the effect of prior processing on strip for roll forming.

Improving gambling survey research using dual-frame sampling of landline and mobile phone numbers

Gambling prevalence studies are typically conducted within a single (landline) telephone sampling frame. This practice continues, despite emerging evidence that significant differences exist between landline and mobile (cell) phone only households. This study utilised a dual-frame (landline and mobile) telephone sampling methodology to cast light on the extent of differences across groups of respondents in respect to demographic, health, and gambling characteristics.

A total of 2,014 participants from across Australian states and territories ranging in age from 18 to 96 years participated. Interviews were conducted using computer assisted telephone interviewing technology where 1,012 respondents from the landline sampling frame and 1,002 from the mobile phone sampling frame completed a questionnaire about gambling and other health behaviours. Responses across the landline sampling frame, the mobile phone sampling frame, and the subset of the mobile phone sampling frame that possessed a mobile phone only (MPO) were contrasted.

The findings revealed that although respondents in the landline sample (62.7 %) did not significantly differ from respondents in the mobile phone sample (59.2 %) in gambling participation in the previous 12 months, they were significantly more likely to have gambled in the previous 12 months than the MPO sample (56.4 %). There were no significant differences in internet gambling participation over the previous 12 months in the landline sample (4.7 %), mobile phone sample (4.7 %) and the MPO sample (5.0 %). However, endorsement of lifetime problem gambling on the NODS-CLiP was significantly higher within the mobile sample (10.7 %) and the MPO sample (14.8 %) than the landline sample (6.6 %).

Our research supports previous findings that reliance on a traditional landline telephone sampling approach effectively excludes distinct subgroups of the population from being represented inresearch findings. Consequently, we suggest that research best practice necessitates the use of a dual- rame sampling methodology. Despite inherent logistical and cost issues, this approach  needs to become the norm in gambling survey research.

Evolution of strain-induced precipitates in a model austenitic Fe-30Ni-Nb steel and their effect on the flow behaviour

The present work investigated the evolution of strain-induced NbC precipitates in a model austenitic Fe-30Ni-Nb steel deformed at 925 °C to a strain of 0.2 during post-deformation holding between 3 and 1000 s and their effect on the reloading flow stress. The precipitate particles preferentially nucleated on the nodes of the periodic dislocation networks constituting microband walls. Holding for 10 s resulted in the formation of fine, largely coherent NbC particles with a mean diameter of ∼5 nm, which displayed a cube-on-cube orientation relationship with austenite and caused the maximum increase in the reloading steady-state flow stress. A further increase in the holding time from 30 to 1000 s led to the formation of semi-coherent, gradually coarser and more widely spaced particles with a mean diameter of 8 nm and above, which led to a gradual decrease in the reloading steady-state flow stress. The holding time increase resulted in progressive disintegration of the dislocation substructure and dislocation annihilation through static recovery processes, which was also reflected by the measured softening fractions. The precipitate particle shape changed during post-deformation annealing from elliptical to faceted octahedral and subsequently to tetra-kai-decahedral. © 2014 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Fabrication and visible-light photocatalytic behavior of perovskite praseodymium ferrite porous nanotubes

Perovskite praseodymium ferrite (PrFeO3) porous nanotubes are prepared by electrospinning of the precursor solution into nanofibers, subsequently by annealing the precursor fibers at a low temperature (e.g. 40 °C) and finally by calcination at a high temperature. The low temperature annealing treatment is found to play a key role in the formation of porous nanotube. The porous tubes show a perovskite-type PrFeO3 crystal characteristic with high optical absorption in the UV-visible region and an energy band gap of 1.97 eV. When compared with PrFeO3 porous nanofibers and PrFeO3 particles, the PrFeO3 porous nanotubes show better visible-light photo-catalytic ability to degrade Rhodamine B in aqueous phase because of the increased surface area and more active catalytic sites on the inner walls and outer surfaces.

The evolution of microbands and their interaction with NbC precipitates during hot deformation of a Fe-30Ni-Nb model austenitic steel

The present work has investigated the evolution of microbands (MBs) and their interaction with strain-induced NbC precipitates during uniaxial compression of a model austenitic Fe-30Ni-Nb steel at 925 °C. The (1 1 0) fibre grains, both without and with copious amounts of precipitates, contained up to large strains crystallographic MBs aligned close to the highly stressed {1 1 1} slip planes having large Schmid factors. The MBs thus maintained their crystallographic character during straining, through continuously rearranging themselves, and did not follow the macroscopically imposed rigid body rotation. During double-pass deformation, fine NbC particles formed at short inter-pass holding remained strongly pinned at small reloading strains and appeared to be dragged by rearranging MB walls. With increasing reloading strain, the fine precipitates became progressively released from the above walls. During reloading after increased holding time, the coarsened particles tended with their increased size to become increasingly detached from the MB walls already at a small strain. The precipitate-free MB wall segments rearranged during straining to maintain their crystallographic alignment, while the detached precipitates followed the sample shape change and rotated towards the compression plane. The MB wall rearrangement generally occurred through cooperative migration of the corresponding dislocation networks.

Extending light-weighting and mass-production of ultra high strength steels via condition-based maintenance

The use of ultra high strength steels (UHSS) in the automotive industry presents a significant opportunity for continued vehicle light-weighting, due to possible strength-to-weight improvements of three to four times that of conventional sheet steel grades. This performance benefit is achievable whist maintaining most of the advantages of low-cost mass-production associated with the cold stamping of sheet steel for automotive body components. However, the introduction of UHSS can result in significantly increased wear of the stamping tools, which is difficult to predict at the design stage and can lead to unexpected process failure during mass-production. Therefore, there is a need to be able to monitor and predict the onset of severe wear, such that the best course of condition-based maintenance can be scheduled and unscheduled stoppages due to tool wear eradicated. This paper describes a novel active monitoring system that is being developed by researchers at Deakin University, The Australian National University and Ford Motor Company, Asia Pacific and Africa. The aim of the active monitoring system is to detect the initial onset of a change of state, such as wear, through the measurement of variables such as punch force and audio signals. A semi-industrial stamping process, using a progressive die setup and high strength steel sheet with hardened tool steel tooling, is the experimental basis for the initial model and system development.