STRESS ANALYSIS

Stress analysis is an engineering (e.g., civil engineering and mechanical engineering) discipline that determines the stress in materials and structures subjected to static or dynamic forces or loads

To determine whether the element or collection of elements, usually referred to as a structure, can safely withstand the specified forces under due consideration of factor of safety.

ANALYTICAL TECHNIQUE  EXPERIMENTAL TECHNIQUE



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Finite element method. Finite difference method, Boundary element method

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Brittle lacquer(Brittle Coat). Strain gauge method. Photo elasticity. X-ray method. Grid technique Acoustoelasticity,etc.

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The brittle-lacquer technique of experimental stress analysis relies on the failure by cracking of a layer of a brittle coating which has been applied to the surface under investigation. The coating is sprayed onto the surface and allowed to air- or heat-cure to attain its brittle properties. Cracking occurs where the strain is greatest, so that an immediate indication is given of the presence of stress concentrations. The cracks also indicate the directions of maximum strain at these points since they are always aligned at right angles to the direction of the maximum principal tensile strain.

This method makes use of a brittle coating also known as brittle lacquer or stress coat which is basically a limed wood rosin K and dibutyl phthalate with carbon disulphide as a solvent.

CRACK PATTERN IN BRITLLE LACQUER

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An appropriate coating for the existing temperature and humidity conditions is selected. The job and the calibration strips are thoroughly cleaned and given an aluminium pre coating to provide a bright background for facilitating the observation of the cracks. The precoating dries in about 15 minutes. Job and the calibration strips are sprayed with brittle coating and permitted to dry for 15 to 24 hours. The coat or lacquer becomes brittle on hardening. At the place in the job where stress pattern and magnitude is to be determined,it is loaded.These stresses in material affect the brittle coat and it cracks a crack pattern in the brittle coat on a job stressed to biaxial tensile stresses. The calibration strip is subjected to biaxial tensile stresses and the (load) point of initial cracking is marked and the strain in the strain scale is read. Stresses are calculated by comparing the results of the stress coat on the job with those of on calibration strip

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PRINCIPLE :  The acoustoelastic stress analysis is based on the fact that an initially isotropic material becomes anisotropic under stress.  The technique of acoustoelastic stress analysis uses the velocity difference in ultrasonic shear waves polarized in principal directions by means of the sing-around method.
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The difference of propogation velocities in shear waves polarised in principal-stress directions is proportional to the principal-stress differences in the plane-stress state. Tokuoka and Iwashimizu established the theoretical background of acoustoelasticity showed that the difference of propagation speeds VT1 and VT2 of the shear waves polarized in principal directions was proportional to the principal-stress difference W1-W2 i.e.,

VT1=Velocity of first shear wave VT2= velocity of second shear wave VT0= Shear wave velocity of stress free isotropic material Q= Modulus of Rigidity Y3= Third order elastic constant.

  

The transducer was attached to the specimen by Canada balsam diluted with Castor oil and, at the same time, it was pressed against the specimen by a spiral spring installed in a setup stand. The transducer is rotatable without demounting it from the specimen during the test by loosening the spring pressure. To determine the basic acoustoelastic coefficient of the material, uniaxial tests were carried out on specimen. The transducer was first polarized in the loading direction and the transit time of the shear wave across the specimen under stress was measured at preselected levels for both loading and unloading. Then the transducer was rotated so that the direction of polarization was perpendicular to the loading direction and measurements of the transit time were carried out similarly.

Advantage :
One of the promising Non- destructive techniques whose results are very close to conventional destructive techniques.

Disadvantage:
Difficult selection of transducer-coupling material. Separation of preferred orientation effect.

The finite element method is a powerful tool for predicting welding residual stresses and distortions . However the phenomena in welding are three dimensional in their nature. Generally, the three dimensional thermal-elastic-plastic FE analysis requires very long computational time and large memory size. To overcome this problem the FRACTAL MULTI-GRID METHOD is proposed . Its potential capability is demonstrated through application to very simple mechanical and thermal problems.

To increase computational Speed. Memory saving

At first level boundary condition is applied to the cell. Use the displacement at 9 nodes obtained at the 1st level as the prescribed displacement at the 4 corners & compute displacement of 4 cells belonging to the 2nd level. Repeat the same steps until we get to lowest level.

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Force the continuity of the displacement at the 4 nodes on the edge of the cell at the lowest level by interpolating the displacement of 2 nodes belonging to the 2 cells sharing the same edge. Compute the unbalanced force at the lowest level. Redistribute the unbalanced force at the 4 middle nodes & 1 center node. Middle Node : Redistribute 1 half of the unbalanced force to the 2 corner nodes on the same edge.

Center Node : Redistribute 1 fourth of the unbalanced force to the four corner nodes of the cell.  Spread the above unbalanced nodal force to the 2 nodes belonging to the cells sharing the same cell according to the ratio of the stiffness.  Compute the correction to the nodal displacement of the cell using the redistributed unbalanced forces with the prescribed correction displacements at the 4 corner nodes.  Repeat steps 2-8 until the norm of the unbalanced force at the lowest level becomes small enough.

X-ray stress analysis is a applications of X-ray diffraction of polycrystalline materials. Not only have residual stress measurements recently become an essential part of materials science, but they are also an indispensable tool in industry and technology. X-ray reveals about the following :
Grain size Orientation of crystals Cold worked ,distorted and internally stressed crystals

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The Laue back reflection method. The rotating crystal method. The Debye-Scherrer powder method.

When a beam of monochromatic x-rays is directed as a narrow pencil at a specimen a metal diffraction takes place. The resultant image is recorded on photographic film as a series of spots and interpretation of pattern leads us to know about the crystal structure of metal.

Interpretation from pattern :

S.No. 1 2 3 4 Back reflection photograph Few clear spots Large number of spots in ring State of metal Coarse grains>0.04mm Fine Grains 0.004mm

Continuous Rings Very fine grains 0.0004mm Spots are Cold Worked irregular in outline and shape

The principle of strain gauge is that the electrical resistance of a conductor changes proportionally to any strain applied to it. Thus, if a short length of wire were bonded to the structure in such a way that it experiences the same deformation as the structure, then by measuring the change in resistance, the strain can be obtained.

Photoelasticity is an experimental method of stress analysis, which utilizes the birefringent phenomenon exhibited by some polymers under load, and has played a significant role in the history of experimental stress analysis.

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