Residual stresses in press-braked stainless steel sections,II: Press-braking operations

The manufacturing process of cold-formed thin-walled steel members induces cold work which can be characterized by the co-existent residual stresses and equivalent plastic strains and has a significant effect on their structural behaviour and strength. The present paper and the companion paper are concerned with the prediction of residual stresses and co-existent equivalent plastic strains in stainless steel sections formed by the press-braking method. This manufacturing process consists of the following two distinct stages: (i) coiling and uncoiling of the sheets, and (ii) press-braking operations. This paper first presents an analytical solution for the residual stresses and the co-existent equivalent plastic strains that arise from the second stage while a corresponding analytical solution for the first stage is presented in the companion paper. In both solutions, plane strain pure bending is assumed and the effect of material anisotropy is taken into account. On the basis of these two analytical solutions, an analytical model is presented to predict residual stresses and equivalent plastic strains in press-braked stainless sections. The predictions of the analytical model are shown to be in close agreement with results from a finite element-based method, demonstrating the validity and accuracy of the analytical model. The analytical model provides a much simpler method for the accurate prediction of residual stresses and equivalent plastic strains in different parts of a press-braked stainless steel section than a finite element-based method.     

Residual stresses in cold-rolled stainless steel hollow sections

Stainless steel exhibits a pronounced response to cold-work and heat input. As a result, the behaviour of structural stainless steel sections, as influenced by strength, ductility and residual stress presence, is sensitive to the precise means by which the sections are produced. This paper explores the presence and influence of residual stresses in cold-rolled stainless steel box sections using experimental and numerical techniques. In previous studies, residual stress magnitudes have been inferred from surface strain measurements and an assumed through-thickness stress distribution. In the present study, through-thickness residual stresses in cold-rolled stainless steel box sections have been measured directly by means of X-ray diffraction and their effect on structural behaviour has been carefully assessed through detailed non-linear numerical modelling. Geometric imperfections, flat and corner material properties and the average compressive response of stainless steel box sections were also examined experimentally and the results have been fully reported. From the X-ray diffraction measurements, it was concluded that the influence of through-thickness (bending) residual stresses in cold-rolled stainless steel box sections could be effectively represented by a rectangular stress block distribution. The developed ABAQUS numerical models included features such as non-linear material stress-strain characteristics, initial geometric imperfections, residual stresses (membrane and bending) and enhanced strength corner properties. The residual stresses, together with the corresponding plastic strains, were included in the FE models by means of the SIGINI and HARDINI Fortran subroutines. Of the two residual stress components, the bending residual stresses were found to be larger in magnitude and of greater (often positive) influence on the structural behaviour of thin-walled cold-formed stainless steel sections.     

Residual stress analysis of structural stainless steel sections

The magnitude and distribution of residual stresses in structural carbon steel sections have been thoroughly investigated. However, few residual stress measurements have been made on structural stainless steel sections. Stainless steel has differing material stress-strain characteristics and thermal properties to carbon steel, both of which influence the formation of residual stresses. This suggests that established carbon steel residual stress models may not be appropriate for stainless steel. With increased use of stainless steel in load bearing applications, it is important to establish the residual stresses that exist within structural members. An experimental program to quantify the residual stresses in stainless steel sections from three different production routes has therefore been carried out. Comprehensive residual stress distributions have been obtained for three hot rolled angles, eight press braked angles and seven cold rolled box sections, with a total of over 800 readings taken. This paper presents the experimental techniques implemented and the residual stress distributions obtained as well as discussing the assumptions commonly made regarding through thickness residual stress variations. In the hot rolled and press braked sections, residual stresses were typically found to be below 20% of the material 0.2% proof stress, though for the cold rolled box sections, whilst membrane residual stresses were relatively low, bending residual stresses were found to be between 40% and 70% of the material 0.2% proof stress.     

Flexural behaviour of stainless steel oval hollow sections

Structural hollow sections are predominantly square, rectangular or circular in profile. While square and circular hollow sections are often the most effective in resisting axial loads, rectangular hollow sections, with greater stiffness about one principal axis than the other, are generally more suitable in bending. Oval or elliptical hollow sections (EHS) combine the aesthetic external profile of circular hollow sections with the suitability for resisting flexure of rectangular sections, whilst also retaining the inherent torsional stiffness offered by all tubular sections. This paper examines the structural response of recently introduced stainless steel oval hollow sections (OHS) in bending and presents design recommendations. In-plane bending tests in the three-point configuration about both the major and minor axes were conducted. All tested specimens were cold-formed from Grade 1.4401 stainless steel and had an aspect ratio of approximately 1.5. The full moment-rotation responses of the specimens were recorded and have been presented herein. The tests were replicated numerically by means of non-linear finite element (FE) analysis and parametric studies were performed to investigate the influence of key parameters, such as the aspect ratio and the cross-section slenderness, on the flexural response. Based on both the experimental and numerical results, structural design recommendations for stainless steel OHS in bending in accordance with Eurocode 3: Part 1.4 have been made.     

Strength enhancements induced during cold forming of stainless steel sections

The material properties of stainless steel are sensitive to plastic deformation which causes an increase in yield strength by a process termed cold working. The different strain paths experienced around cold-formed cross sections during manufacture create unique material strength distributions for sections from different forming routes and also influence residual stress patterns. The research program presented herein has examined experimentally the material and residual stress distributions found in two types of cold-formed sections-cold-rolled box sections and press-braked angles. Predictive tools to harness the observed strength enhancements have been proposed and incorporated into models. Subsequent comparisons have shown that these strength enhancements, in particular those observed for cold-rolled box sections, should be employed in structural design to avoid considerable underestimation of member resistance.     

Experimental investigation of residual stresses in roller bent wide flange steel sections

Residual stresses in straight hot rolled wide flange sections are well documented and have been investigated in the recent past. However, to the knowledge of the authors, residual stress measurements have not been published on roller bent wide flange sections. Straight sections are curved into roller bent ones at ambient temperatures by means of the roller bending process. Since roller bent sections underwent severe plastic deformation during the forming process, the well-known residual stress patterns from hot rolling may not be appropriate for the roller bent steel. Roller bent sections can be applied in halls, roofings and bridges, thereby acting as structural arches and it is important that a realistic residual stress pattern is implemented when assessing their load carrying capacity. An experimental program has been carried out to investigate the residual stresses in roller bent wide flange sections bent about the strong axis. Residual stresses were measured with the sectioning method. The experimental technique was investigated with respect to possible temperature influence and repeatability of the measurements. Experimental values revealed that the residual stress pattern and magnitude in roller bent sections is different when compared to their straight counterparts.     

Strengthening of circular hollow steel tubular sections using high modulus CFRP sheets

This paper describes the behaviour of very high strength (VHS) circular steel tubes strengthened by carbon fibre reinforced polymer (CFRP) and subjected to axial tension. A series of tests were conducted with different bond lengths and number of layers. The distribution of strain through the thickness of CFRP layers and along the CFRP bond length was studied. The strain was found to generally decrease along the CFRP bond length far from the joint. The strain through the thickness of the CFRP layers was also found to decrease from the bottom to top layer. The effective bond length for high modulus CFRP was established. Finally empirical models were developed to estimate the maximum load for a given CFRP arrangement.     

Residual behavior of steel rebars and R/C sections after a fire

The mechanical properties of various steel bars exposed to high temperature (“residual” properties) are experimentally investigated up to 850 °C, with reference to a number of steel and bar types (carbon and stainless steel; quenched and self-tempered bars; hot-rolled and cold-worked bars; smooth and deformed bars). The aim is to clarify to what extent the thermal sensitivity of the different bars affects the ultimate capacity of a typical R/C section subjected to an eccentric axial force, past a fire (“residual” capacity). As usual in the design of R/C sections under combined bending and axial loading, the ultimate behavior is represented through the “M–N envelopes”, where the materials strength decay due to high temperature is taken into account. The results show that quenched and self-tempered bars (QST), very popular in Europe, are more temperature-sensitive above 600 °C than the carbon-steel bars extensively used in the States and nowadays rarely used in Europe. Furthermore, the best response is exhibited by the stainless-steel bars, provided that they are hot rolled, as it is generally the case for medium- and large-diameter bars. Similar conclusions can be drawn for the sections reinforced with the different bar types.     

Experimental and numerical investigations of cold-formed stainless steel tubular sections subjected to concentrated bearing load

Experimental and numerical investigations of cold-formed stainless steel square and rectangular hollow sections subjected to concentrated bearing load are presented in this paper. A total of 124 data are presented that include 64 test results and 60 numerical results. The tests were performed on austenitic stainless steel type 304, high strength austenitic and duplex material. The measured web slenderness value of the tubular sections ranged from comparatively stocky webs of 6.2 to relatively more slender webs of 61.4. The tests were carried out under end and interior loading conditions. A non-linear finite element model is developed and verified against experimental results. Geometric and material non-linearities were included in the finite element model. The material nonlinearity of the flat and corner portions of the specimen sections were carefully incorporated in the model. It was shown that the finite element model closely predicted the web crippling strengths and failure modes of the tested specimens. Hence, the model was used for an extensive parametric study of cross-section geometries, and the web slenderness value ranged from 52.0 to 206.7. The test results and the web crippling strengths predicted from the finite element analysis were compared with the design strengths obtained using the American, Australian/New Zealand and European specifications for stainless steel structures. A unified web crippling equation with new coefficients for cold-formed stainless steel square and rectangular hollow sections subjected to concentrated bearing load is proposed. It is demonstrated that the proposed web crippling equation is safe and reliable using reliability analysis.     

Effects of residual stresses on the uniaxial ratcheting behavior of a girth-welded stainless steel pipe

International Journal of Steel Structures - This study attempts to characterize analytically the uniaxial ratcheting behavior of a girth-welded stainless steel pipe. Finite element (FE) simulation...     

Effects of anchoring tensile stresses in axially loaded plates and sections

Thin-walled compression members are commonly designed on the assumption that the loaded edges remain straight. Under this assumption, tensile stresses develop in the most flexible parts of the component plates at advanced local buckling deformation, and thus are assumed to be ‘anchored’ at the ends. However, current design rules for plate elements, such as the Winter formulae, are partly based on tests in which the load was applied by use of rigid platens that did not permit tensile stresses to develop. There exists an apparent inconsistency between the assumption of straight loaded edges and the use of a design curve calibrated from tests in which the loaded edges of component plates may not have remained straight.This paper addresses this apparent inconsistency by comparing finite element solutions for the conditions of straight loaded edges and loading by use of a contact surface between the plate edge and a non-deformable rigid body end platen, where there is no constraint for the plate edge to remain in contact with the rigid body. Solutions are provided for a single half-wavelength of unstiffened and stiffened plate elements simply supported along three and four edges, respectively. The effect of multiple half-wavelengths is also investigated, as is the effect of interaction between elements in practical sections comprising stiffened and unstiffened elements.     

Residual stresses in autofrettaged vessel made of functionally graded material

We used an extension of the Variable Material Property method for materials with varying elastic and plastic properties to evaluate the residual stresses in an autofrettaged thick vessel made of functionally graded metal–ceramic composite. It is shown that the reinforcement of the metal vessel by ceramic particles, with an increasing ceramic volume fraction from inner to outer radius, increases the magnitude of compressive residual stresses at the inner section of an autofrettaged vessel and thus, could lead to better fatigue life and load-carrying capacity of the vessel. A parametric study is carried out to highlight the role of ceramic particle strength and spatial distribution, as well as the autofrettage pressure on the induced residual stresses in a thick vessel.     

Fire testing and design of stainless steel structures

Despite significant progress in recent years in the development of room temperature design guidance for stainless steel structures, fire resistant design has received relatively little attention. This paper reports on studies carried out to investigate the performance of unprotected stainless steel beams and columns in fire. Material tests were carried out on five grades of stainless steel to determine strength and stiffness retention factors at elevated temperatures; both strength and stiffness retention were shown to be superior to that of carbon steel beyond 600 ^°C. The temperature development characteristics of a range of stainless steel sections were investigated, and compared to those of carbon steel sections. Full scale fire tests were conducted on six stainless steel columns, and four stainless steel beams. Finite element modelling of the tests was carried out, and parametric studies were performed to supplement the test data. All tests were carried out as part of the European project ‘Development of the use of stainless steel in construction’. Design recommendations for stainless steel columns and stainless steel beams supporting a concrete slab, based on the ECCS model code for fire engineering, were validated against the test and finite element results. These recommendations have been incorporated into the Euro Inox/SCI Design Manual for Structural Stainless Steel, and implemented in Eurocode 3: Part 1.2, with minor adjustments for consistency with carbon steel.     

Prediction of residual stresses and strains in cold-formed steel members

The objective of this paper is to provide an unambiguous mechanics-based prediction method for determination of initial residual stresses and effective plastic strains in cold-formed steel members. The method is founded on basic physical assumptions regarding plastic deformations and common industry practice in manufacturing. Sheet steel coiling and cross-section roll-forming are the manufacturing processes considered. The structural mechanics employed in the method are defined for each manufacturing stage and the end result is a series of closed-form algebraic equations for the prediction of residual stresses and strains. Prediction validity is evaluated with measured residual strains from existing experiments, and good agreement is shown. The primary motivation for the development of this method is to define the initial state of a cold-formed steel member for use in a subsequent nonlinear finite element analysis. The work also has impact on our present understanding of cold-work of forming effects in cold-formed steel members.     

Postbuckling and ultimate state of stresses in steel plate girders

In [1], nonlinear large deflection finite element analysis was implemented to depict the characteristics of the shear failure mechanism of steel plate girders. That paper aimed at clarifying how–when–why and where plastic hinges form in flanges. The present paper extends those results to the state of stresses in web plates. It is shown that although the principal compressive stresses in the center of the web plates remain constant after an elastic buckling, they do increase considerably in other regions. In addition, the angles at which tension fields form; and the ultimate strength of plate girders is discussed and compared to those obtained by different theoretical and experimental hypotheses.     

General behaviour and effect of rigid and non-rigid end post in stainless steel plate girders loaded in shear. Part I: Experimental study

To better understand the response of stainless steel plate girders loaded in shear, an experimental campaign was carried out at UPC as a part of extensive research on shear behaviour of stainless steel girders.A total of 8 stainless steel plate girders were tested. The primary design variables were, apart from the aspect ratio and slenderness of the web panel, the rigid or non-rigid condition of the end post. In parallel, a numerical model was developed in code ABAQUS [Hibbit, Karlsson and Sorensen Inc., ABAQUS/Standard, Version 6.3. User’s manual. Rhode Island (USA); 2002]. The tests results served as a basis for calibration of numerical models and furthermore for the development and verification of a new approach to structural stainless steel design.Different responses and modes of failure in shear were observed and special attention was taken of the effect of the rigidity of the end post during the analysis of results. The comparative analysis of the experimental results with current codes’ approaches clearly shows that shear design procedures included in Eurocode 3 Part 1.4 [European Committee for Standardisation. ENV 1993-1-4. Eurocode 3: Design of steel structures. Part 1.4: General rules—supplementary rules for stainless steel. Brussels; 1996], which specifically deals with stainless steel structures, are overly conservative.     

混凝土模拟液中碳素钢-不锈钢连接时的腐蚀规律

为了探明混凝土中普通碳素钢与不锈钢搭配使用时的腐蚀规律,使用含氯离子的混凝土模拟液模拟氯盐污染混凝土环境,测试分析了一系列不锈钢、碳素钢试件的动电位极化曲线(CP)、电化学阻抗谱(EIS)和零电阻电流(ZRA)。研究结果表明:连接不锈钢的碳素钢腐蚀速度明显加快,工程应用时宜采取绝缘措施以降低腐蚀风险;碳素钢-碳素钢之间由于锈蚀程度不同也存在电偶腐蚀,但相比不锈钢-碳素钢连接其腐蚀速度较慢且腐蚀规律不太稳定;在氧气含量一定情况下,受腐蚀产物的影响试件后期腐蚀速度普遍减小。     

不锈钢钢带在自粘卷材生产中的应用

介绍了利用不锈钢铜带的平整性、输运性、耐温性。通过刮涂法生产自粘防水卷材的一种工艺，并通过疲劳寿命分析和应力分析解出了钢带使用张力的范围及振动特性。     

Design of cold-formed stainless steel tubular T- and X-joints

This paper describes the numerical investigation of cold-formed stainless steel tubular T-joints, X-joints and X-joints with chord preload using finite element analysis. The stainless steel joints were fabricated from square hollow section (SHS) and rectangular hollow section (RHS) brace and chord members. The geometric and material nonlinearities of stainless steel tubular joints were carefully incorporated in the finite element models. The joint strengths, failure modes as well as load-deformation curves of stainless steel tubular joints were obtained from the numerical analysis. The nonlinear finite element models were calibrated against experimental results of cold-formed stainless steel SHS and RHS tubular T- and X-joints. Good agreement between the experimental and finite element analysis results was achieved. Therefore, an extensive parametric study of 172 T- and X-joints was then carried out using the verified finite element models to evaluate the effects of the strength and behaviour of cold-formed stainless steel tubular joints. The joint strengths obtained from the parametric study and tests were compared with the current design strengths calculated using the Australian/New Zealand Standard for stainless steel structures, CIDECT and Eurocode design rules for carbon steel tubular structures. Furthermore, design formulae of cold-formed stainless steel tubular T- and X-joints are proposed. A reliability analysis was performed to assess the reliability of the current and proposed design rules. It is shown that the design strengths calculated using the proposed equations are generally more accurate and reliable than those calculated using the current design rules.     

Computational modelling of flange crushing in cold-formed steel sections

The computational modelling of the flange crushing phenomenon in cold-formed steel profiles is described in this paper, with particular emphasis to the development of shell finite element (SFE) models and performance of quasi-static analyses with an explicit integration scheme. Web crippling failure is widely recognised as the most relevant collapse mode of cold-formed steel members subjected to transverse concentrated loads. However, it has been experimentally and numerically observed that a somewhat different collapse mode may occur, due to the heavy stress concentrations stemming from the adoption of narrow bearing plates. This phenomenon, termed flange crushing, should not be confused with web crippling. Usually, the web crippling phenomenon is numerically investigated by means of non-linear static SFE models with an implicit integration scheme. In this study, SFE models are developed in ABAQUS code to study the flange crushing failure of a plain channel beam subjected to Internal Two Flange (ITF) loading conditions. These models are described in detail, as well as additional modelling concerns regarding quasi-static analyses and the explicit integration method. Different parameters are discussed in this article and the numerical results obtained are commented throughout. Such parameters include the (i) SFE type and mesh, (ii) load rate, mass scaling, adoption of smoothed displacement amplitude curves and control of inertial effects, (iii) contact and friction definitions, (iv) effects of forming cold-work and manufacturing process and (v) geometrical imperfections. Finally, the load–displacement response obtained with the quasi-static model and an equivalent non-linear static analysis are compared with the experimental test curves. It is concluded that very good results are achieved with the quasi-static approach, not only in terms of the ultimate load prediction, but also regarding the post-collapse load–deflection curve and the failure mechanism.