Experimental study of strain fields during shearing of medium and high-strength steel sheet

There is a shortage of experimentally determined strains during sheet metal shearing. These kinds of data are a requisite to validate shearing models and to simulate the shearing process. In this work, strain fields were continuously measured during shearing of a medium and a high strength steel sheet, using digital image correlation. Preliminary studies based on finite element simulations, suggested that the effective surface strains are a good approximation of the bulk strains below the surface. The experiments were performed in a symmetric set-up with large stiffness and stable tool clearances, using various combinations of tool clearance and clamping configuration. Due to large deformations, strains were measured from images captured in a series of steps from shearing start to final fracture. Both the Cauchy and Hencky strain measures were considered, but the difference between these were found negligible with the number of increments used (about 20 to 50). Force-displacement curves were also determined for the various experimental conditions. The measured strain fields displayed a thin band of large strain between the tool edges. Shearing with two clamps resulted in a symmetric strain band whereas there was an extended area with large strains around the tool at the unclamped side when shearing with one clamp. Furthermore, one or two cracks were visible on most of the samples close to the tool edges well before final fracture. The fracture strain was larger for the medium strength material compared with the high-strength material and increased with increasing clearance.

Improvements to the design of Litesteel Beams undergoing lateral distortional buckling

An Australian manufacturer has recently developed an innovative group of cold-formed steel hollow flange sections, one of them is LiteSteel Beams (LSBs). The LSB sections are produced from thin and high strength steels by a patented manufacturing process involving simultaneous cold-forming and dual electric resistance welding. They have a unique geometry consisting of rectangular hollow flanges and a relatively slender web. The LSB flexural members are subjected to lateral distortional buckling effects and hence their capacities are reduced for intermediate spans. The current design rules for lateral distortional buckling were developed based on the lower bound of numerical and experimental results. The effect of LSB section geometry was not considered although it could influence the lateral distortional buckling performance. Therefore an accurate finite element model of LSB flexural members was developed and validated using experimental and finite strip analysis results. It was then used to investigate the effect of LSB geometry. The extensive moment capacity data thus developed was used to develop improved design rules for LSBs with one of them considering the LSB geometry effects through a modified slenderness parameter. The use of the new design rules gave higher lateral distortional buckling capacities for LSB sections with intermediate slenderness. The new design rule is also able to accurately predict the lateral distortional buckling moment capacities of other hollow flange beams (HFBs).

Numerical modelling of light gauge cold-formed steel compression members subjected to distortional buckling at elevated temperatures

Fire safety design of building structures has received greater attention in recent times due to continuing loss of properties and lives during fires. However, fire performance of light gauge cold-formed steel structures is not well understood despite its increased usage in buildings. Cold-formed steel compression members are susceptible to various buckling modes such as local and distortional buckling and their ultimate strength behaviour is governed by these buckling modes. Therefore a research project based on experimental and numerical studies was undertaken to investigate the distortional buckling behaviour of light gauge cold-formed steel compression members under simulated fire conditions. Lipped channel sections with and without additional lips were selected with three thicknesses of 0.6, 0.8, and 0.95 mm and both low and high strength steels (G250 and G550 steels). More than 150 compression tests were undertaken first at ambient and elevated temperatures. Finite element models of the tested compression members were then developed by including the degradation of mechanical properties with increasing temperatures. Comparison of finite element analysis and experimental results showed that the developed finite element models were capable of simulating the distortional buckling and strength behaviour at ambient and elevated temperatures up to 800 °C. The validated model was used to determine the effects of mechanical properties, geometric imperfections and residual stresses on the distortional buckling behaviour and strength of cold-formed steel columns. This paper presents the details of the numerical study and the results. It demonstrated the importance of using accurate mechanical properties at elevated temperatures in order to obtain reliable strength characteristics of cold-formed steel columns under fire conditions.

Shear tests of lipped chanel beams with web openings

Cold-formed steel members are increasingly used as primary structural elements in the building industries around the world due to the availability of thin and high strength steels and advanced cold-forming technologies. Cold-formed steel lipped channel beams (LCB) are commonly used as flexural members such as floor joists and bearers. However, their shear capacities are determined based on conservative design rules. Current practice in flooring systems is to include openings in the web element of floor joists or bearers so that building services can be located within them. However, limited research has been undertaken on the shear behaviour and strength of LCBs with web openings. Hence a detailed experimental study involving 32 shear tests was undertaken to investigate the shear behaviour and strength of LCBs with web openings. Simply supported test specimens of LCBs with an aspect ratio of 1.0 and 1.5 were loaded at mid-span until failure. This paper presents the details of this experimental study and the results of their shear capacities and behavioural characteristics. Experimental results showed that the current design rules in cold-formed steel structures design codes are very conservative for the shear design of LCBs with web openings. Improved design equations have been proposed for the shear strength of LCBs with web openings based on the experimental results from this study.

Finite element analyses of lipped channel beams with Web openings in shear

Cold-formed steel members are increasingly used as primary structural elements in buildings due to the availability of thin and high strength steels and advanced cold-forming technologies. Cold-formed lipped channel beams (LCB) are commonly used as flexural members such as floor joists and bearers. Shear behaviour of LCBs with web openings is more complicated and their shear capacities are considerably reduced by the presence of web openings. However, limited research has been undertaken on the shear behaviour and strength of LCBs with web openings. Hence a numerical study was undertaken to investigate the shear behaviour and strength of LCBs with web openings. Finite element models of simply supported LCBs with aspect ratios of 1.0 and 1.5 were considered under a mid-span load. They were then validated by comparing their results with test results and used in a detailed parametric study. Experimental and numerical results showed that the current design rules in cold-formed steel structures design codes are very conservative for the shear design of LCBs with web openings. Improved design equations were therefore proposed for the shear strength of LCBs with web openings. This paper presents the details of this numerical study of LCBs with web openings, and the results.

Shear buckling characteristics of cold-formed steel channel beams

Cold-formed steel members are increasingly used as primary structural elements in the building industries around the world due to the availability of thin and high strength steels and advanced cold-forming technologies. Cold-formed lipped channel beams (LCB) are commonly used as flexural members such as floor joists and bearers. However, their shear capacities are determined based on conservative design rules. For the shear design of LCB web panels, their elastic shear buckling strength must be determined accurately including the potential post-buckling strength. Currently the elastic shear buckling coefficients of LCB web panels are determined by assuming conservatively that the web panels are simply supported at the junction between their flange and web elements. Hence finite element analyses were conducted to investigate the elastic shear buckling behavior of LCBs. An improved equation for the higher elastic shear buckling coefficient of LCBs was proposed based on finite element analysis results and included in the ultimate shear capacity equations of the North American cold-formed steel codes. Finite element analyses show that relatively short span LCBs without flange restraints are subjected to a new combined shear and flange distortion action due to the unbalanced shear flow. They also show that significant post-buckling strength is available for LCBs subjected to shear. New equations were also proposed in which post-buckling strength of LCBs was included.

The modulus of elasticity of steel - is it 200 GPa?

In cold-formed steel construction, the use of a range of thin, high strength steels (0.35 mm thickness and 550 MPa yield stress) has increased significantly in recent times. A good knowledge of the basic mechanical properties of these steels is needed for a satisfactory use of them. In relation to the modulus of elasticity, the current practice is to assume it to be about 200 GPa for all steel grades. However, tensile tests of these steels have consistently shown that the modulus of elasticity varies with grade of steel and thickness. It was found that it increases to values as high as 240 GPa for smaller thicknesses and higher grades of steel. This paper discusses this topic, presents the tensile test results for a number of steel grades and thicknesses, and attempts to develop a relationship between modulus of elasticity, yield stress and thickness for the steel grades considered in this investigation.

Numerical modelling and design of lipped channel beams subject to shear

Cold-formed steel members are increasingly used as primary structural elements in buildings due to the availability of thin and high strength steels and advanced cold-forming technologies. Cold-formed lipped channel beams (LCB) are commonly used as flexural members such as floor joists and bearers. Many research studies have been carried out to evaluate the behaviour and design of LCBs subject to pure bending actions. However, limited research has been undertaken on the shear behaviour and strength of LCBs. Hence a numerical study was undertaken to investigate the shear behaviour and strength of LCBs. Finite element models of simply supported LCBs with aspect ratios of 1.0 and 1.5 were considered under a mid-span load. They were then validated by comparing their results with test results and used in a detailed parametric study based on the validated finite element models. Numerical studies were conducted to investigate the shear buckling and post-buckling behaviour of LCBs. Experimental and numerical results showed that the current design rules in cold-formed steel structures design codes are very conservative for the shear design of LCBs. Improved design equations were therefore proposed for the shear strength of LCBs. This paper presents the details of this numerical study of LCBs and the results.

The effect of crack closure on the grain size dependence of fatigue crack growth threshold

Recent studies (I-7) clearly indicate a strong dependence of fatigue threshold parameter, A K on grain size in several alloy systems. Attempts to explain these observations on the basis of crat~tortuosity (1,8), fracture surface roughness (5,9) and crack closure (6) appear to present a fairly clear picture of the mechanisms that cause a reduction in crack growth rates at threshold. In general, it has been shown that coarse grained microstructures exhibit higher fatigue threshold in low carbon steels (1,5) aluminium alloys (7) and titanium alloys (6). In spite of these observations, there exists (10-1#) considerable uncertainity about the manner in which the AK~L depends on prior austenitic grain size in quenched and tempered steels. Studies in quenched and tempered steels demonstrating both an increase (3,12,14) as well as a decrease (11,12) in AKth with an increase in prior austenitic grain size can be sought to illustrate this point. Occasionally , the absence of any sensitivity of AKth to the variations in prior austenitJc grain size has also been reported (11,13). While a few investigators (5-7) comfortably rationalised the grain size effects on AK~L on the basis of crack closure by a comparison in terms of the closure-free component of the thresho~Ifc~, AK -f such an approach has yet to be extended to high strength steels, An attempt has been made in t~et ,pthrg sent study to explai. n the effect of pri, or austeniti.c grain size on &Kth on the basis of crack closure measurements in a high strength steel.

The fracture toughness of bulk metallic glasses

Stiffness, strength, and toughness are the three primary attributes of a material, in terms of its mechanical properties. Bulk metallic glasses (BMGs) are known to exhibit elastic moduli at a fraction lower than crystalline alloys and have extraordinary strength. However, the reported values of fracture toughness of BMGs are highly variable; some BMGs such as the Zr-based ones have toughness values that are comparable to some high strength steels and titanium alloys, whereas there are also BMGs that are almost as brittle as silicate glasses. Invariably, monolithic BMGs exhibit no or low crack growth resistance and tend to become brittle upon structural relaxation. Despite its critical importance for the use of BMGs as structural materials, the fracture toughness of BMGs is relatively poorly understood. In this paper, we review the available literature to summarize the current understanding of the mechanics and micromechanisms of BMG toughness and highlight the needs for future research in this important area.

Experimental and computational investigation of the roll forming process

One of the first questions to consider when designing a new roll forming line is the number of forming steps required to produce a profile. The number depends on material properties, the cross-section geometry and tolerance requirements, but the tool designer also wants to minimize the number of forming steps in order to reduce the investment costs for the customer. There are several computer aided engineering systems on the market that can assist the tool designing process. These include more or less simple formulas to predict deformation during forming as well as the number of forming steps. In recent years it has also become possible to use finite element analysis for the design of roll forming processes. The objective of the work presented in this thesis was to answer the following question: How should the roll forming process be designed for complex geometries and/or high strength steels? The work approach included both literature studies as well as experimental and modelling work. The experimental part gave direct insight into the process and was also used to develop and validate models of the process. Starting with simple geometries and standard steels the work progressed to more complex profiles of variable depth and width, made of high strength steels. The results obtained are published in seven papers appended to this thesis. In the first study (see paper 1) a finite element model for investigating the roll forming of a U-profile was built. It was used to investigate the effect on longitudinal peak membrane strain and deformation length when yield strength increases, see paper 2 and 3. The simulations showed that the peak strain decreases whereas the deformation length increases when the yield strength increases. The studies described in paper 4 and 5 measured roll load, roll torque, springback and strain history during the U-profile forming process. The measurement results were used to validate the finite element model in paper 1. The results presented in paper 6 shows that the formability of stainless steel (e.g. AISI 301), that in the cold rolled condition has a large martensite fraction, can be substantially increased by heating the bending zone. The heated area will then become austenitic and ductile before the roll forming. Thanks to the phenomenon of strain induced martensite formation, the steel will regain the martensite content and its strength during the subsequent plastic straining. Finally, a new tooling concept for profiles with variable cross-sections is presented in paper 7. The overall conclusions of the present work are that today, it is possible to successfully develop profiles of complex geometries (3D roll forming) in high strength steels and that finite element simulation can be a useful tool in the design of the roll forming process.

Caracterização metalográfica de um aço de fases complexas (CP)

Pós-graduação em Engenharia Mecânica - FEG

Caracterização microestrutural e mecânica de aços bifásicos de ultra-alta resistência como médio teor de carbono

Pós-graduação em Engenharia Mecânica - FEG

CHARACTERIZATION OF A AISI/SAE 4340 STEEL IN DIFFERENT MICROSTRUCTURAL CONDITIONS

The 4340 are classified as ultra-high strength steels used by the aviation industry and aerospace applications such as aircraft landing gear and several structural applications, usually in quenched and tempered condition. In this situation occurs reduction of toughness, which encourages the study of multiphasic and bainitic structures, in order to maintain strength without loss of toughness. In this study, ferritic-pearlitic structure was compared to bainitic and martensitic structure, identified by the reagents Nital, LePera and Sodium Metabisulfite. Sliding wear tests of the type pin-on-disk were realized and the results related to the microstructure of these materials and also to their hardnesses. It is noted that these different microstructures had very similar behavior, concluding that all three tested pairs can be used according to the request level.

Heat Treatment and Yb-Fiber Laser Welding of a Maraging Steel

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)