Beruflich Dokumente
Kultur Dokumente
by,
Amit H. Varma
May 2, 2003
Michigan Department of Transportation
Conference Room
INTRODUCTION
Some examples of fatigue prone details
Component / Detail Initial Defect or Fatigue Category
Condition
Cover-plated beams Weld toe E
Flange gussets Weld toe E or E
Eyebars Stress corrosion, Forge Initial crack
laps
Longitudinal stiffener Lack of fusion /poor weld Large initial crack
Box girder corner welds Transverse weld Large-initial crack
Coped Members Flame-cut notch Initial defect
Pin Plates Frozen pins Out-of-plane
Transverse stiffeners Shipping and handling Out-of-plane
Diaphragm connection Web gaps Out-of-plane
plates
Gusset plates Lateral bracing Out-of-plane
FUNDAMENTAL FATIGUE OF METALS
Metal fatigue is a well-known phenomenon
Wohler - German engineer fatigue of railroad car axles
Alternating cyclic stresses (even in the elastic range) cause
fatigue failure in metal components or details.
Fatigue crack initiation
Fatigue crack propagation
Brittle fracture
Consider the stress state in the vicinity of the crack tip in a structure
subjected to tensile stresses normal to the plane of the crack
magnitude described by the stress intensity factor K , which implicitly
I
accounts for the effects of stress, crack size and geometry, and structure
Stress state in the vicinity of a crack tip loaded in tension
FATIGUE CRACK PROPAGATION
KI can be calculated analytically for various structural
configurations, crack geometries, and loadings
For all cases KI = C a
KI has units of ksi in
Unstable crack growth occurs when KI
exceeds KIc, which is the critical
stress intensity factor for the material
Material A m
Martensitic steels 0.66 x10-8 3.25
For bridge components and details, initial crack or defects are present in the
form of flaws or defects
Crack initiation life is negligible
Crack propagation life dominates (N = N ) f
If the initial flaw size is a i and the final flaw size at fracture is af
af Nf
da
da
m
dN
m
A C a
Therefore
dN ai A( C a ) m
Ni
af
A1 N
da m
ai A ( C a )m
Let A1 = Therefore 1
A1 m
And N
FATIGUE LIFE
1
A1 m
where, m = 3 for ferrite-perlite steels
N
The live-load stress range is used as the relevant force effect for
designing bridge details for fatigue.
Research has shown that the total stress is not relevant for welded details
Residual stresses are not considered explicitly for fatigue design
Using the stress range as the design parameter implicitly includes the effects
of residual stresses on welded details
Fatigue design load = vehicular live load (LL) due to fatigue design truck
i i Qi
and thecorresponding impact factor (IM) and centrifugal force (CE)
Q=
where, i = load modifiers, i = load factor = 0.75 and
The load factor of 0.75 reflects a load level representative of the truck
population with large number of repetitive cycles and fatigue effects.
FATIGUE DESIGN TRUCK
Steel bridges are designed for the live-load (LL) stress range caused by the
fatigue design truck, which has a set distance of 30 ft. between the 32 kip loads,
and is slightly different than the design truck
30-0
The live load stress due to the passage of the fatigue load is approx. one-half of
the heaviest truck expected to cross the bridge in 75 years.
Only one fatigue truck is considered for design irrespective of the number of
design lanes.
No multiple presence of live load and no lane loads are considered.
Dynamic load allowance (IM). The live load stress caused by the fatigue design
truck is to be increased by the dynamic load allowance factor of 15%
FATIGUE LOADING
The frequency of occurrence of the fatigue design load is estimated
as the single-lane annual daily truck traffic (ADTT)SL
In the absence of better information ADTT) SL can be estimated as
(ADTT)SL = p x ADTT
ADTT = number of trucks per day in one direction averaged over the
design life Number of Lanes p
available to Trucks
1 1.00
2 0.85
3 or more 0.80
The same fatigue resistance curves are applicable to both redundant and
non-redundant members.
FATIGUE DETAIL CATEGORIES
Structural components and details are grouped into eight detail
categories according to their fatigue resistance
A and B detail categories are for plain members and well-prepared
welded connections in built-up members without attachments
D and E detail categories are assigned to fillet-welded attachments and
groove-welded attachments without adequate transition radius or with
unequal plate thickness
C detail category can apply to welded attachments with transition radius
greater than 150 mm and proper grinding of welds.
FATIGUE DETAIL CATEGORIES
FATIGUE DETAIL CATEGORIES
FATIGUE DETAIL CATEGORIES
FATIGUE DETAIL CATEGORIES
PLAIN MEMBERS BUILT-UP MEMBERS
A Rolled surface B
Cont. welded
B Painted weath. B
E Eyebars E
Cover plates
E
B B
B
LONGITUDINALLY LOADED ATTACHMENTS
End welds End welds not End welds End welds not
C C
Longer is worse
ground smooth ground smooth ground smooth ground smooth
Longer is worse
D D
Larger radius better
Groove welded
C D E
C D E
D E
E
TRANSVERSE LOADED ATTACHMENTS
Fillet welded
Welds parallel to direction of stress
D E
E
18 C and above 1
19 C to 34 C 2
34 C to 51 C 3
BRITTLE FRACTURE CONSIDERATIONS
Fracture-critical member (FCM) is defined as a member with tensile
stress whose failure is expected to cause the collapse of the bridge
material in a FCM is required to exhibit greater toughness and ability to absorb
more energy without fracture than a non-fracture critical member
The c-to-c pitch of shear connectors shall not exceed 24.0 in. and
shall not be less than six stud diameters
FATIGUE OF SHEAR CONNECTORS
The fatigue resistance of an individual shear connector
Z r = d2 > 2.75 d2
where = 34.5 2.28 Log N
d = diameter of stud and N = number of cycles
The clear depth of concrete cover over the tops of the shear
connectors should not be less than 2.0 in.
Shear connectors should penetrate at least 2.0 in. into the deck
FATIGUE DESIGN
30-0
We have already designed a composite steel bridge. The span length of the bridge
is 34 ft. The roadway width is 44 ft.
The selected beam is W24 x 68 with a in. thick cover plate narrower than the
flange
Clearly the bending moment is smaller at the ends and we can curtail the cover-
plate to save some money. Lets see?
The cover plate can be curtailed to the point where the moment is small enough
for the steel beam alone to carry it
But, the fatigue stress range at the end of the cover plate must be OK!
FATIGUE DESIGN
Step I Estimate number of fatigue cycles
Cover plate (narrower than the flange) with flange thickness < 0.8 in.
Therefore, Category E detail
From the table: A = 11.0 x 10 and (F) = 4.5 ksi
8
TH