POLICAB

Laboratrio de Anlise de Tenses

DMC - FURG

FURG

Mechanical Engineering Design: The Necessity of the Experimental Data and Experimental Parameters to Validate the Theoretical Models
Prof. Fulvio Chimisso, D. Sc. POLICAB Stress Analysis Laboratory DMC - FURG BRAZIL

EXPERIMENTAL PROCEDURES X THEORETICAL MODELS, ALONG THE LAST CENTURIES

If we dont know the mechanical behavior of the materials (mechanical characteristic parameters) it is impossible to obtain reasonable answers through theoretical models.

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

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MEDICAL, ENVIRONMENT, and HUMANISTIC RESEARCH FIELDS EXPERIMENTAL PROCEDURES

There are research fields where experimental data are essentials:

The increasing or the decreasing population (turtles, fishes, etc). of a The growth of a specific disease in human or animal population.

Will be related with a exponential equation like as

Y = X
Y

Where Y = population, X = time (or the number of events) and and are the constants determinate through the collected data

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

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MECHANICAL ENGINEERING UNDERGRADUATE STUDENTS: GREAT DIFFICULTIES FOR THE EXPERIMENTAL MECHANICAL DESIGN APPROACH.

STUDENTS - PROCEDURES & MANUALS - MACHINE DESIGN BOOKS (tables) EXERCISES SAMPLES COMPONENTS DESIGN

WHEN A NEW MACHINE DESIGN COMPONENT (WITH A NEW MATERIAL) WILL BE MADE, RULES, PROCEDURES AND PROPER NEW PARAMETERS WILL BE ESTABLISHED.

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

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USUAL MECHANICAL ENGINEERING DESIGN PROCEDURES:

EXPERIMENTAL FIELD (Prototype tests) THEORETICAL FIELD (modeling: analytical or/and numerical) EXPERIMENTAL FIELD (Mechanical parameters determination) MACHINE DESIGN FIELD (stress-strain relations, fatigue, vibrations)

(1)
DESIGN OF STRUCTURES

(2)
DESIGN OF MACHINE ELEMENTS

(3)
EXPERIMENTAL FIELD (Mechanical proofs in real scale) STRUCTURES DESIGN WITH LARGE SAFETY COEFFICIENTS

MODELS WILL BE DEVELOPED (Design with tendency curves behavior)

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

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THE EVOLUTION: EXPERIMENTAL X MECHANICAL DESIGN

1. The design and the experimental practice in the 16 th century. A sample problem; 2. The theory of elasticity and the stress strain problem; 3. The fatigue problem and the usual and unusual solutions; 4. The CDM - Continuum Damage Mechanic and the related dificulties; 5. New fields and new problems: new technologies; 6. The POLICAB know-how; 7. The POLICAB research field.

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

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A few years ago

Thin-walled dome:

In the last centuries the experimental results had played decisively in the engineering field. The membrane answer give us:

Spherical shape, equal thickness all over and loaded by its own weight where is the weight per unit area.

p = R t

(a) (b)

t (thickness) h

2rt sen + A = 0

p where p = - cos

Considering the area for a spherical segment, A = 2a2(1-cos), and solving the equations (a) and (b) for the stresses, we find:

POLICAB
Laboratrio de Anlise de Tenses

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= and a = t

a t (1 + cos ) 1 cos 1 + cos

1. The meridional stress, , is always negative, so, always compressive; 2. But the tangential stress, , becomes tensile when > 52o.

That was a problem for the cathedrals building in the middle age. The Leonardo da Vinci experiment:
Thin rope with concentrated weights along his length:

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

FURG

THE CRISIS OF THE THEORY OF THE ELASTICITY

Strong difficulties to solve mechanical problems design through analytical answers. A body with a unusual shape. PHOTOELASTIC The usual experimental answers: - Photoelasticity, - Strain-gages The numerical answers: - Finite Difference Method; - Finite Element Method, FEM.

Stress Concentration Factors. Sample: Hook.

Hook made with polyester resin.

FEM
TODAY: FEM + Experimental Methods

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

FURG

The structural Integrity problem and the associated damage models and theories Usual Mechanical Fatigue Design Steps : i) Loads measure; ii) Cycles counting; iii) Material characteristic parameters; iv) Damage increase models. DAMAGE MODELS AND THEORIES: a) Models who describe the initial crack: - SN method or Infinite Life Design; - N (Coffin Manson) method or Safe Life Design. b) Models who describe the crack propagation: - da/dN or Fail Safe Design method (LEFM application); -Damage-tolerant Design method (da/dN associated with high quality control). c) And nowadays, CDM - Continuum Damage Mechanics models: Theory of Potentials (Free energy and dissipative)

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

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The FATIGUE Problem

The firstdata of fatigue-catastrophic ruptures: rotate bending

The behavior of a material in the presence of a variable state of stress and strain:

(t) ; (t)

How quantify the strength reduction ?

The SN Method:
A. Whler ( Royal Lower Silesian Railways Engineer) between 1852 and 1869 1th fatigue testing machine.

Whler basic rules (analysis and experiments).

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Laboratrio de Anlise de Tenses

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Rotate bending test

CP

F
bending
Rotation:

Bending moment

A A A

The Moore fatigue testing Machine

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The SN Curve (Moore curve): experimental points

Where A, no rupture.

Mechanical Characteristics: Fatigue Endurance Limits,

A Rupture No rupture N

Sn , SN

Log S

Sn= SU Where < 1

steel alumnium

SN = aN b

or

log SN log S'n10 3 log S'n log S'n10 3

logN - log10 = log - log103

103

106

Log N

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Endurance Limit Reduction Factors:

Where Kf = 1 + q(Kt 1) is the Fatigue Stress Concentration Factor.

C CC C 1 S n = L S D W S'n CC Kf

q= 1+

1 a r

is the sensibility coefficient and (a) is the Neuber Constant NEW EXPERIMENTAL PARAMETERS: SURFACE COEFFICIENT LOAD COEFFICIENT DIAMETER COEFFICIENT WELD COEFFICIENT SHOCK COEFFICIENT CS CL CD CW CC

POLICAB
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A SN Fatigue Procedure:

log S Sn 103

a SY Sn 106

Sn 106

Sn 106 CLCSCDCW / CC

1a 1m SU m

103

106

log N

SY

1a ae

von Mises Goodman Design Procedure:

M a 1 M m + = SU Sn N

POLICAB
Laboratrio de Anlise de Tenses

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The N (Manson-Coffin) Method: Low cycle fatigue

8 6 4 Load [kN] 2 0 -2 -4 -6 -8 -0.015

More material constants: f , f , b , c, n , K

Prescribed Strain 1th up: static curve.

-0.01

-0.005

0 Strain [m/m]

0.005

0.01

0.015

Hysteresis Loop:

Hysteresis loop. SYC p T e

T = + 2 2E 2K '

1 n'

Manson Coffin equation:

T = 2

e p + 2 2

T 'f (2 N )b + 'f (2 N )c = 2 E

STABLE CYCLE

POLICAB
Laboratrio de Anlise de Tenses

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NOWADAYS: CDM CONTINUUM DAMAGE MECHANIC

It is a incipient design methodology: a lot of new parameters will be introduced. Two Potentials are postulated: 1. Energy Potential (or Thermodynamic Potential), , based on the Helmholtz Free Energy,

= ( - p , )
2. And a Dissipative Potential, , to define the variables evolution,

& & (, B , p , ) < 0 p = 0 e = 0 .

With the Free Energy and the Dissipative Potentials we define systematic procedures to obtain complete sets of Constitutive Equations, thermodynamically admissible.

POLICAB
Laboratrio de Anlise de Tenses

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SAMPLE 1. AN ELASTO-PLASTIC CONTINUUM DAMAGE MODEL CDM related through the evolution of the Constitutive equations:

& & & & = (1 D) E ( p ) DE ( p )

& & & x = (1 D)(a p b x) Dac

& & & y = (1 D )v1v2 e v2 p p D v1 (1 e v2 p ) + y

x & = x
p

& p =

& & c=p

b x a

& D=

E ( 2S0

p 2

e v2 p + ac + 2 v1 p + v2
2

2 D + p y + C 2 z

POLICAB
Laboratrio de Anlise de Tenses

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Where <a> = max (0,a) and is the Lagrange multiplier:

0 ,

F 0 ,

F = 0

More new mechanical coefficients/parameters: Sample specimen - a and b related to the cinematic hardening; - 1 and 2 related to the isotropic hardening; - S0 related to the damage growth.

1,5 1,4 1,3 1,2 1,1 1 0,9 0,8 0,7 0,6 0 200 400 600 800 1000 Nmeros de Ciclos para R uptura(N)

Deformao(%

Modelo

Ex perim entos

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Laboratrio de Anlise de Tenses

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SAMPLE 2. A VISCO-ELASTIC CONTINUUM DAMAGE MODEL OFFSHORE SYNTHETIC MOORING ROPE CASE:
Creep testing (CT) is widely used on synthetic mooring ropes research as the basic experimental technique to promote the incidence of rupture. With this methodology, however, the assessment of "threshold values" to be used as design parameters is not a simple task in the present state of art of the area. This limitation induces the use of the CT as "go-no go" test for mooring ropes selection and some basic information required, for instance, time to failure in service in different loading conditions, can not be inferred by this approach. Consider a tension specimen with gauge length Lo and (nominal) cross-section, A0, submitted to a prescribed load.

The basic idea is to introduce a macroscopic variable D [0, 1], related to the fraction of broken yarns on the specimen:

n D= N

Where N is the total number of yarns in the rope or leg (subrope) and n is the number broken yarns.

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If D = 1, the rope is virgin, since there are no broken yarns, and, if D = 1, it is completely broken and can no longer resist to mechanical loading. The following model, restricted to tensile loading is proposed to describe the coupling between visco-elasticity and the damage induced by creep phenomenon.

=(1-D)E ( - v )

-X d v &v = = Sg dt K with X = (1 - D) [v1(1-exp(-v 2 v ))] and Sg=max {0,-X}

Creep damage

Fatigue damage

dD R & = [WE + WV ] + [S* WE ] * dt with WE = 1 1 2 E( - V ) and WV = v1 V + exp( v 2 V ) 2 v2

Where the variables and are defined as follow: = F/Ao

;

= L/Lo

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

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EXPERIMENTAL CREEP ANALYSIS ON SYNTHETIC FIBERS

Results for the creep rupture tests performed on the multi-filaments of HMPE SK75 and SK78:
Time for rupture [s] Applied Load [% Nominal YBL] 90 85 80 75 70 60 HMPE SK75 1.40 13.82 44.22 397.40 4,995.40 25,620 HMPE SK78 15.52 418.00 4,016 5,500 9,296 71,930

The following figures show, as an example, the strain curves for creep obtained in the tests of the multi-filaments of HMPE SK75 and SK78 with 60% of its nominal rupture loads and with an initial load rate of 500N/min. It can be observed the first, second and third creep stages, with the material failure. The secondary stage has the tendency to become linear along the time.

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Laboratrio de Anlise de Tenses

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Creep rupture tests for HMPE - SK75, 60% YBL.

Creep rupture tests for HMPE - SK78, 60% YBL.

The creep experimental parameters obtained, will be introduced into the CDM viscoelastic model

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

FURG

Sample 3. A Elasto-Viscoplastic Model (anisothermal with Damage) State Equations

= (1 D )E p ( 0 ) B p = (1 D )b 1 e dp

[(

B c = (2 / 3)X = (1 D )ac ; X = X 1 + X 2 and c = c1 + c 2 B D = E 1 / 2 p ( 0 ) p + b p + (1 / d )e dp + + (3 / 4) a 1 (c1 ) + a 2 (c 2 )

2

] ] [ ]

[ (

][

c2 2 c1 log( )d + ( 0 ) 2 0

POLICAB
Laboratrio de Anlise de Tenses

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Evolution Laws

& p = (3 / 2) & & p = p

X R p K

X X

& & c1 = p (2 / 3) 1 X 1 p a & 1 & & c 2 = p (2 / 3) 2 X 2 p a & 2

D & =B p & D S0

hP & & & & & ( ) c + r = p + Rp + Xc B D D x x A R X B D & p & & & & p + (2 / 3) c D +

With more experimental parameters: c, a1, a2

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

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THE ACTUAL MATCH: WHAT WE HAVE TO DO REGARDING THE NEW TECHNOLOGIES AND THE NEW PROBLEMS IN A LOT OF NEW MECHANICAL ENGINEERING FIELDS ?
The POLICAB Experience: offshore cases for FPU (oil Floating Production Units) in very deep waters.
With the development of oil fields in deep waters over 1000 meters, the replacement of steel ropes used for the mooring of floating structures, by other with lesser linear weight, became a necessity. In shallow waters, the petroleum drilling and production flotation units are anchored by conventional systems: chains and steel ropes in catenaries configurations. For deep waters the Taut-Leg system was developed. The architecture of a synthetic rope in the mooring of oceanic platforms consists of: multi-filaments (yarns) forming a leg, some twisted legs forming one subrope and finally several subropes, all together in parallel, forming a rope. Nowadays these deep water mooring ropes, are made of polyester (PET) and they provide the necessary conformity to the taut-leg system by means of the natural elastic properties of the fiber, which replaces the need of long catenary configurations used in the conventional mooring systems.

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Laboratrio de Anlise de Tenses

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FPS (Floating Production System) FPSO (Floating, Production, Storage and Offloading):

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Tug launcher:

Torpedo prepared for the launch operation.

Detail of the tug stern roller at the beginning of the mooring rope launching operation:

Courtesy of PETROBRAS Brazilian Petroleum Co.

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Servo-hydraulic 1500 ton push-pull testing machine, to test offshore mooring ropes, in real scale.

Prepare ropes to transport and tug operation

(Courtesy of CSL - Cordoaria So Leopoldo, Rope-Makers, Brazil)

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Laboratrio de Anlise de Tenses

DMC - FURG

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PROBLEMS ASSOCIATED TO THE DESIGN OF MECHANICAL COMPONENTS USED IN OFFSHORE PETROLEUM EXTRATION IN DEEP AND ULTRA DEEP WATERS:
Logistic; Weight; Cost; Maintenance; Alternative developments; Necessary design innovations; Classifying structures and components; Normalizing general procedures; And so on.

The experimental work developed into the POLICAB Stress Analysis Laboratory, to help the design of mechanical components used in offshore petroleum extraction in deep and ultra deep waters.

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG Usual ropes architecture ULTRASEVEN ROPE ARCHITECTURE:

FURG

Overture of a damaged rope at POLICAB

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SOME PROBLEMS ASSOCIATED TO MOORING ROPES

-The architecture; - The extreme external loads involved (storm conditions); -The sub-rope state of stress and strain; - The careful to made the sub-ropes and the jackets; -The stress and strain safety coefficient; - The creep analysis; EXPERIMENTAL CREEP ANALYSIS ON FIBER ROPES FOR OFFSHORE MOORING SYSTEMS
CREEP HMPE SK75 X SK78 - 30%YBL
24 22 20 18 16
24 22 20 18 16

CREEP HMPE SK75 X SK78 - 15%YBL

SK75 - CP10 SK78 - CP1 SK78 - CP2 SK78 - CP3 SK78 - CP4

Strain [%]

Strain [%]
12000000

14 12 10 8 6 4 2 0
0 1000000 2000000 3000000 4000000 5000000 6000000 7000000 8000000 9000000

SK78 SK78 SK78 SK78 SK75 SK75

10000000

- CP5 - CP6 - CP7 - CP8 - CP18 - CP19

11000000

14 12 10 8 6 4 2 0 0 1000000 2000000 3000000 4000000 5000000 6000000 7000000 8000000 9000000

10000000

11000000

12000000

Time [s]

Time [s]

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Synthetic Mooring Rope Jackets Submitted to Abrasive Actions: A Methodology Proposed to Determine Superficial Wearing Behavior

Objectives:

establish superficial wearing tests procedures, emphasizing the number of cycles, the contact surfaces (abrasive material), the kind of solicitation and its intensity, and criteria to stop the tests; establish wearing analysis criterions of the specimens; analyze the results obtained from comparative wearing curves, traced for several materials.

Tension Submerged in Water Tension Tension + Bending

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Laboratrio de Anlise de Tenses

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Standard test with sub rope exposure

Polyester 10500 MIXED T120 Comparison Between Solicitations:

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Laboratrio de Anlise de Tenses

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POLYESTER x POLYBLEND Comparative Curves in Tension

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CURRENTLY EXPERIMENTAL DEVELOPMENTS AT POLICAB

ABRASION TEST PROCEDURE: JACKET ON STEEL FOR SYNTHETIC MOORING ROPES
The objective: To establish a test procedure to determine the abrasion resistance of the jacket of a synthetic rope for station keeping.

WEARING: DEVELOPING A TEST SYSTEM.

Monofilament and multifilament yarn wearing test: with and without yarn marine finish.

Rotating Drum

Rope tightening and tensioning system Clamped rope end or fixed rope end with translation movement

POLICAB
Laboratrio de Anlise de Tenses

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ACTUAL AND FUTURE WORKS AND RESEARCH INTO POLICAB

1. OFFSHORE, MOORING ROPES:

1.1. Time and environment effects due the way it is stored: spoil research (mechanical changes in synthetic mooring ropes due the way it is stored); 1.2. Yarn creep for several synthetic materials used to make offshore mooring ropes (Nylon, Polyester, HMPE, Polypropylene, Polyblend...); 1.3. Scale factors and fatigue research for Polyester offshore mooring ropes; 1.4. Continuum Damage Mechanics for viscoelastic materials.

2. OFFSHORE, TUG OPERATIONS AND WORK ROPES: 2.1. Abrasion and superficial wearing in synthetic rope covers (jackets): optimization; 2.2. Abrasion resistance of the jacket of a synthetic rope for station keeping.

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3. OFFSHORE, ACESSORIES AND FACILITIES: 3.1. Theoretical development and experimental modeling of terminals for synthetic ropes; 3.2. Experimental Research about adhesive joint; 3.3. Testing Machine Clamps development.

4. FISHING EQUIPMENTS: 4.1. Mechanical strength of polyamide monofilaments; 4.2. Mechanical strength of fishing nets.

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

FURG

Despite the theoretical modeling development for the mechanical engineering design, we continue to have a real necessity of experimental procedures to determine the material parameters to evaluate, improve and validate those models.

POLICAB Stress Analysis Laboratory

Sunset at POLICAB

DMC FURG RIO GRANDE RS BRASIL fulvio@dmc.furg.br

POLICAB
Laboratrio de Anlise de Tenses

DMC - FURG

FURG