International Journal of Fatigue 25 (2003) 359–369 www.elsevier.com/locate/ijfatigue Comparison of different calculation methods for structural stresses at welded joints O. Doerk, W. Fricke ∗, C. Weissenborn Technical University Hamburg-Harburg, Laemmersieth 90, Hamburg 22305, Germany Received 24 May 2002; received in revised form 29 October 2002; accepted 18 November 2002 Abstract Different methods and procedures exist for the computation of the structural hot-spot stress at welded joints. These are either based on the extrapolation of stresses at certain reference points on the plate surface (or edge) close to the weld toe—as known from experimental investigations—or on the linearization of stresses in the through-thickness direction. Procedures for the application of both methods to finite element analysis have recently been proposed in the literature. In the present paper, the different methods are reviewed and applied to four different details in order to compare the methods with each other and to illustrate the differences. Conclusions are drawn with respect to their accuracy and sensitivity to finite element meshing. 2003 Elsevier Science Ltd. All rights reserved. Keywords: Welded joint; Structural stress; Hot-spot stress; Finite element method; Stress analysis 1. Introduction The crack initiation and early propagation at weld toes is governed by the local stress distribution around the weld. Its analysis and assessment with respect to fatigue has already a rather long history. According to [18], first investigations were performed in the 1960’s by several researchers, including Peterson, Manson and Haibach, to relate the fatigue strength to a local stress or strain measured at a certain point close to the weld toe, for example at a distance of 2 mm [7]. Although the characteristic fatigue strength related to this local stress shows fairly small scatter it has been shown e.g. in [1] that it is still affected by the local notch at the weld toe and, therefore, not independent from local notch geometry. Investigations of relatively thick tubular joints have shown that the local notch effect of the weld toe affects the stress in the region up to 0.3⫺0.4·t (t ⫽ plate thickness) away from the weld toe. This resulted in the 1970’s in the development of the well-known hot-spot stress approach with the definition of reference points for stress evalu- Corresponding author. Tel.: +49-40-428-32-3148; fax: +49-40428-32-3337. E-mail address: w.fricke@tu-harburg.de (W. Fricke). ∗ ation and extrapolation at certain distances away from the weld, which depend on the plate or shell thickness. This development, which was reviewed a. o. by van Wingerde et al. [19], was particularly successful for the fatigue strength assessment of tubular joints due to their complex joint geometry and high local bending of the tubular walls. First attempts to apply the approach to welded joints at plates were already seen in the early 1980’s. Remarkable investigations were performed in Japan to analyse the stress concentration due to the local structural geometry of ship hull details, which were summarized a. o. by Matoba et al. [11]. The design stress was obtained from finite element analyses by linearization of the stress through the plate thickness. Radaj [17] summarized these and other investigations and defined the structural stress at the hot spot (weld toe) as the surface stress which can be calculated at the hot spot in accordance with structural theories used in engineering. He demonstrated that the structural stress can be analysed either by surface extrapolation or by linearization, e.g. through the wall thickness, in order to exclude the local non-linear stress peak caused by the weld toe. In the early 1990’s, Petershagen et al. [16] derived a generalized hot-spot stress approach for plate structures using Radaj’s effective notch stress approach [17] and 0142-1123/03/$ - see front matter 2003 Elsevier Science Ltd. All rights reserved. doi:10.1016/S0142-1123(02)00167-6 360 O. Doerk et al. / International Journal of Fatigue 25 (2003) 359–369 Nomenclature b B F l M SCF t width of doubling plate width of parent plate force element length bending moment stress concentration factor plate thickness applied it to complex welded structures [4]. Detailed recommendations concerning stress determination for fatigue analysis of welded components were given by Niemi [12]. However, several applications showed that the stress results are still affected by the finite element meshing and element properties. Additional recommendations for finite element modelling and hot-spot stress evaluation were given by Huther et al. [9] and by Fricke [6], the latter based on extensive round-robin stress analyses of several details. Special considerations have been shown to be necessary for in-plane notches such as welded edge gussets, where plate thickness is no more a relevant parameter for the definition of the reference points for stress evaluation. Niemi and Tanskanen [13] as well as Fricke and Bogdan [5] proposed alternative procedures for the hot-spot stress analysis in such cases, using absolute distances for the reference points. A comprehensive IIWguidance for the structural hot-spot stress approach is currently under preparation [14]. Dong [2] utilized the structural stress definition by Radaj [17] and evaluated the structural stress directly at the weld toe position from finite element results by using principles of elementary structural mechanics. Mesh insensitivity is claimed and demonstrated by several examples, however, mainly on 2D basic joints [2], [3]. In this paper, the different methods for structural stress evaluation are explained in more detail and compared with each other. Afterwards, their application is illustrated by several 2D and 3D examples, showing the similarities of the methods and answering the question, how far mesh-insensitivity can be reached. It should be emphasized that the structural stress approach is restricted to the fatigue strength assessment of weld toes, where cracks start from the surface of the structure. Cracks starting from the root of not fully penetrated welds are not covered and require a different assessment procedure. w x, y, z d s sm sb t attachment width coordinates distance normal stress membrane stress bending stress shear stress 2. Evaluation of structural stresses from finite element models 2.1. Finite element modelling of welded structures As mentioned in the introduction, different types of weld toes can be identified, see Fig. 1, which require different stress evaluation techniques: a) weld toe on the plate surface at the end of an attachment b) weld toe at the plate edge at the end of an attachment c) weld toe along the weld of an attachment (the more highly stressed of both weld toes) Types a) and c) are in principle similar, however, the influence of modelling is particularly large at the ends of welded attachments, i.e. at type a) and b), where the local stress singularity is more pronounced due to the additional stress concentration at the V-shaped corner. In order to limit the computational effort, relatively simple models and coarse meshes are preferred in practice. Basically, two types of finite element modelling are usual, which are illustrated in Fig. 2 by the example shown above: Fig. 1. Types of weld toes. O. Doerk et al. / International Journal of Fatigue 25 (2003) 359–369 Fig. 2. Typical finite element models and stress evaluation paths. 1. using plate or shell elements which are arranged in the middle plane of the plates. The weld is frequently omitted, except in cases with plate offsets (e.g. doubler plates) or welds close to each other, where interaction effects occur. In such cases the weld can be modelled by vertical or inclined plate elements or by rigid links (constrained equations). The plate or shell elements should generally contain improved inplane behaviour to model steep stress gradients. 2. using solid elements allowing the weld to be easily modelled with prismatic elements. If isoparametric 20-node elements are applied, one element is sufficient in thickness direction due to the quadratic displacement function and linear stress distribution. In connection with reduced integration, the linear part of the stresses can directly be evaluated. 361 For type a) and c) weld toes, the IIW recommendations [8,14] propose a linear extrapolation over two reference points, which are located 0.4·t and 1.0·t away from the hot spot, where t is the thickness of the adjacent plate (Fig. 3.1). The stresses are typically evaluated at nodal points, so that the length of the first element is 0.4·t and the second 0.6·t. In case of a coarser mesh with higher order elements, having lengths equal to t, the stresses in the surface centres of solid elements or at mid-side nodes of shell elements may be evaluated and extrapolated over 0.5·t and 1.5·t (see Figs. 2 and 3.2), as proposed by some ship classification societies. At type a) weld toes, however, the width of the solid element or the two shell elements in front of the hot spot should not exceed either two times the plate thickness t or the attachment width w (=attachment thickness plus two weld leg lengths). The situation is different for type b) weld toes, i.e. at plate edges. As plate thickness is not relevant for the element size nor the location of the reference points, fixed reference points are proposed. Following the proposal by Niemi and Tanskanen [13] to apply quadratic extrapolation over three points, 4 mm, 8 mm and 12 mm away from the hot spot, element lengths of 4 mm or even better 2 mm are required to obtain stresses at nodal points not affected by the stress singularity (Fig. 3.3). The alternative proposal by Fricke and Bogdan [5] implies a linear extrapolation of stresses obtained from the mid-side points of higher-order elements (e.g. isoparametric 8-node shell elements) with 10 mm length and depth, which means that the stresses are extrapolated over points 5 mm and 15 mm away from the hot spot (Fig. 3.4). 2.2. Structural stress evaluation by surface stress extrapolation The ‘classical’ way of evaluating the structural stress at the hot spot is the linear or quadratic extrapolation over two or three reference points in a similar way as done experimentally with strain gauges. Fig. 2 shows typical stress evaluation paths. In case of shell models without weld representation it is recommended to extrapolate the stress to the structural intersection point as modelled in order to avoid stress under-estimation due to the decreased stiffness of the model [6]. Fig. 3. Extrapolation of surface stresses to the hot spot acc. to [14]. 362 O. Doerk et al. / International Journal of Fatigue 25 (2003) 359–369 2.3. Structural stress evaluation according to Dong [2] The structural stress evaluation method proposed by Dong [2] generally focusses on the linearization through the wall thickness directly at the hot spot, however, depends on the type of modelling. For solid models, where the element stresses might be disturbed by the singularity at the weld toe, the element stresses are evaluated at a certain distance d away from the weld toe, e.g. equal to the element length, see Fig. 4. Assuming equilibrium between the axial and shear stresses acting here (Section B-B) and in the section directly at the weld toe (Section A-A), the linear part of the latter can directly be derived (stresses acting on the other sides of the element are neglected). Using trapezoidal integration for n ⫹ 1 equally spaced nodes over the plate thickness yields two equations for sm and sb: 冕 t 1 1 [s ⫹ 2·sxx,1 ⫹ … sm ⫽ sxx(z)·dz ⫽ t 2·n xx,0 0 ⫹ 2·sxx,n⫺1 ⫹ sxx,n] 冕 t 冕 t t2 t2 t2 [s sm ⫹ sb ⫽ sxx(z)·dz⫺d· txz(z)·dz ⫽ 2 6 6·n2 xx,0 0 For a shell model, the structural stress can be evaluated directly at the hot spot because the linear stress distribution is already assumed in the elements, see Fig. 5. In order to avoid inaccuracies due to stress distribution assumed in the element formulation, the structural stress is calculated directly from the nodal forces and moments at the element edge in question. A multi-linear stress distribution is assumed for several elements along the weld which is derived from an equation system for the stress values at the element corners. By using these stresses, mesh insensitivity is claimed by Dong [2] even for hot spots with high stress singularity, i.e. types a) and b) in Fig. 1. 0 ⫹ 6·sxx,1·z2 ⫹ 12·sxx,2 ⫹ … ⫹ (n⫺1)·6·sxx,n⫺1 t ⫹ (3n⫺1)·sxx,n]⫺d [txz,0 ⫹ 2·txz,1 ⫹ … ⫹ 2·txz,n⫺1 2·n ⫹ txz,n] Fig. 4 shows the stress linearization through the whole plate thickness t, resulting in the structural stress as defined by Radaj [17]. Alternatively, the linear stress can be derived for part of the thickness t1, which allows the structural stress to be derived for a crack having propa- Fig. 4. gated only through a part of the thickness. In this case, the stresses acting at the lower boundary of the area, i.e. in the depth t1, have to be included in the a.m. equations, because the lower boundary is no more a free surface. In thick section joints and some other joint configuration, such as fillet welds that are symmetric with respect to geometry and loading, there is a non-monotonic trough-thickness stress distribution. In these cases the linearization is also performed to a finite depth t1, which is equal to t/2 in case of symmetry. Structural stress evaluation for solid models (acc. to [2]). 3. Examples In the following, four examples with different types of weld toes are described, where the methods mentioned above are applied to derive the structural hot-spot stress, i.e. 앫 surface stress extrapolation acc. to IIW [8,14], i.e. linearly over 0.4 t /1.0 t for type a) and c) joints and quadratically over 4 mm /8 mm /12 mm for type b) joints in connection with element lengths of at least 0.4 t or 4 mm, respectively (Figs. 3.1 and 3.3) 앫 surface stress extrapolation over 0.5 t /1.5 t (5 mm and 15 mm for type b) joints) in connection with relatively coarse meshes, having elements with quadratic Fig. 5. Structural stress evaluation for shell models (acc. to [2]). O. Doerk et al. / International Journal of Fatigue 25 (2003) 359–369 shape function and lengths of 1.0t or 10 mm, respectively (Figs. 3.2 and 3.4) 앫 structural stress evaluation acc. to Dong [2], using meshes with different element sizes. All calculations were performed by the authors on the basis of the references given. The element type and weld representation have not been varied within each comparison. 3.1. Plate lap fillet weld The first example concerns a 2D example, the plate lap fillet joint described in [2]. Fig. 6a illustrates the onesided lap joint, which is subjected to an axial force F. The weld toe belongs to type c) according to Fig. 1. Due to the eccentricity of the lap joint and the boundary conditions at the ends, a constant bending moment without any shear force is acting in the plate in front of the weld. Therefore, a constant structural stress is acting which is determined by the stiffness of the actual structure. 363 The application of the structural stress approach according to Dong [2] yields almost the same structural SCF for several mesh densities, as shown in Fig. 6d. As no shear stress is acting in the plate, the stress evaluation can simply be reduced to a linearization through the thickness at any section in the right part, yielding a structural stress SCF of approximately 1.19. The same value is achieved by extrapolating the surface stresses, see Fig. 7. As expected, the mesh density plays almost no role also in the case of surface stress extrapolation. The constant structural stress distribution would even allow any location of the reference points, as long as they are beyond 0.4 t. Fig. 7. Plate fillet lap joint and results obtained for surface stress extrapolation. Fig. 6. Plate fillet lap joint and results obtained by Dong [2]. 364 O. Doerk et al. / International Journal of Fatigue 25 (2003) 359–369 3.2. One-sided doubling plate The second example is the one-sided doubling plate shown in Fig. 8, where the critical weld toe on the plate surface belongs to type c) in Fig. 1. The model was investigated in a Japanese research project [20]. The example is similar to the first one, however, the round doubling plate causes a non-uniform stress distribution in the transverse direction. The example was also investigated in the round-robin analysis described by Fricke [6], where different techniques of modelling the one-sided doubling plate by shell elements were applied. In the present analysis, the doubling plate was modelled by solid elements, allowing the weld to be realistically considered. Fig. 9 shows three different finite element models. In all cases, 20-node solid elements with reduced integration order were used. One element was arranged over the plate thickness, while the element lengths in front of the weld toe ranged from approx. 0.4–2 t. The computed stress distribution in front of the weld toe is plotted in Fig. 10. In contrast to the previous study [6], no stress magnification due to weld distortion was considered. For this reason, the measurement results from Yagi et al. [20] have not been included in Fig. 10, because these were obviously affected by this. Although the resulting stresses are fairly close together, a slight influence of the element size can be observed. The extrapolation of the surface stresses to the hot spot, performed for the associated models and indicated by arrows in Fig. 10, yields hot-spot stress ratios of 1.25 (over 0.4 t /1.0 t) and 1.26 (over 0.5 t /1.5 t). The round-robin study [6] showed a higher scatter (±6%) due to the application of different element types and particularly due to simplified weld modelling in case of shell models, where plate connections and rigid links were used. A scatter of approximately 10% is contained in the results based on the approach by Dong [2], which are plotted on the left side of Fig. 10. The structural stress in this example is obviously not insensitive to the mesh density. The aforementioned scatter due to different element types and simplified modelling may additionally occur. Fig. 8. One-sided doubling plate investigated by Yagi et al. [17]. Fig. 9. Different finite element meshes for modelling the one-sided doubling plate (1/2-model). Fig. 10. Surface stress and structural stress ratio for one-sided doubling plate. O. Doerk et al. / International Journal of Fatigue 25 (2003) 359–369 In order to clarify the reasons for this mesh-sensitivity, the geometry of the one-sided doubling plate has been varied. For the sake of simplification, a rectangular doubling plate with constant length (60 mm), but varying width b has been chosen. The thickness of the doubling plate is 10 mm. The dimensions of the parent plate are B ⫽ 240 mm and t ⫽ 15 mm. Fig. 11 shows three models with different ratios b/B, ranging from 1/12 (shallow longitudinal stiffener) to 1/1 (2D case). The element length in front of the doubling plate was again varied from 0.4 t to 2.0 t. Fig. 12 shows the structural stress evaluated at the centre line according to Dong [2]. It can clearly be seen that the difference between the results becomes larger if 365 Fig. 12. Structural stress according to Dong [2] evaluated from different meshes of rectangular doubling plates. the concentration becomes more localized. The reason is seen in the neglect of vertical shear stresses acting on the transverse element sides in the equilibrium equation described in section 2.3. 3.3. Bracket toe The third example concerns a bracket toe, which was investigated within the European Research Project FatHTS [15]. Fig. 13 shows the test model with a diagonally acting hydraulic cylinder, which produces a combination of axial force, shear force and bending moment in two horizontal and vertical I-beams. The critical position is the bracket toe, which exists four times in each test model. The plate thickness of the flange is 20 mm, while the bracket is 12 mm thick. Full penetration welding was applied with a leg length of the fillet weld reinforcement of 8.5 mm. During the investigation, strain measurements and finite element calculations were performed. Fig. 14 shows two different finite element models of the critical area based on above described recommendations, where the element length in front of the bracket corresponds to the flange thickness. Fig. 15 compares the computed Fig. 11. Finite element models of rectangular doubling plates having different width. Fig. 13. Bracket investigated by Paetzold et al. [15]. 366 O. Doerk et al. / International Journal of Fatigue 25 (2003) 359–369 Fig. 14. Shell and solid finite element models of the bracket with longitudinal stress distribution. Fig. 15. Stress distribution in front of the bracket from measurements and f.e. models (Fig. 14). longitudinal stress in front of the hot spot with measured values for a cylinder force of 100 kN. Apart from the measured stress close to the hot spot, which is affected by the local notch, the agreement is very good. Only the shell model is considered for the present comparison of the different methods. 8-noded quadratic shell elements have been chosen to represent the I-beam, the bracket and the flange. The weld was not modelled as frequently done in practice. In total six meshes have been created with element sizes in front of the bracket toe ranging from 0.4 t × t / 2 to 2 t × 2 t. Half the attachment width (w / 2 ⫽ 14.5 mm) was partly taken for the element width as recommended by Niemi [14] and Fricke [6]. The resulting stress distribution is shown in Fig. 16. The stress singularity influences the results close to the hot spot. However, the structural hot-spot stress derived from surface extrapolation is almost the same for both alternative methods mentioned above. A slight stress under-estimation can be observed when comparing the results with Fig. 15—an effect which has frequently been found in connection with shell models. The restriction of the element width to w/2 has only a small effect on the results in this example. The results obtained by application of Dong’s method are generally higher and show a very large scatter. This is obviously due to the stress singularity, as the local stress becomes infinite if the element size approaches zero. The method [2] as applied to this model is highly mesh-dependent and not able to yield a reasonable structural stress for simplified models. The surface stress extrapolation method has, of course, also problems in such cases, however they seem to be less severe. The mesh density effect is normally related only to the elements in front of the hot spot. However, Fig. 17 shows that also the modelling of other areas—in this case the bracket—may strongly affect the results. A coarse modelling of the bracket toe would increase the local stress by approximately 10% and, thus, closing the gap between shell and solid models. This means that we Fig. 16. Stress distribution in front of the bracket toe and structural hot-spot stresses for various shell models. O. Doerk et al. / International Journal of Fatigue 25 (2003) 359–369 Fig. 17. Stress distribution in front of the bracket toe for two different meshes of the bracket. have to accept an additional scatter in the finite element results due to the meshing around the critical area. 3.4. Fillet weld around plate edge The last example is a flat bar welded to an I-beam, where the critical hot spot is located at the plate edge, see upper part of Fig. 18, i.e. it belongs to type b) 367 according to Fig. 1. The model was investigated experimentally by Kim et al. [10]. It was also included in the round-robin study [6]. Again, shell modelling with 8-noded elements was chosen for the present finite element analysis. The weld was modelled in a simplified way as illustrated in Fig. 18. In this way, the correct weld toe position was kept. The area in front of the weld toe was modelled in three different ways by choosing element lengths ᐉ=2 mm, ᐉ=5 mm and ᐉ=10 mm, respectively. Fig. 19 shows the computed stress distribution at the plate edge of the flat bar close to the weld. The force F was chosen such that a unit nominal stress is acting at the welded toe. As expected for in-plane notches, the stress distribution is affected by the stress singularity, showing increased stresses in the elements adjacent to the notch. The stress extrapolation yields a stress value of 1.77 MPa for the fine mesh (quadratic extrapolation) and 1.68 MPa for the coarse mesh (linear extrapolation), which means a slight difference between the two methods. The difference is higher than expected from the former investigation [5], where only 2D structures with 135° and 90° corners have been analysed. Dong’s method was applied for an assumed crack depth of 10 mm, defining the end of the fatigue life for this specimen. The structural stress computed for the three meshes in accordance with 2.3 shows only little scatter, however, the stress is higher that that obtained from surface extrapolation. It should be mentioned here that the calculated structural stress is higher than the measured one and that the corresponding fatigue life prediction has shown to be very conservative for this example [6]. 4. Conclusions From the application of different structural stress evaluation methods to four examples of welded plate Fig. 18. Flat bar welded to an I-beam and modelling of the critical area around the weld toe. Fig. 19. Stress distribution in front of the fillet weld and structural hot-spot stresses for various models. 368 O. Doerk et al. / International Journal of Fatigue 25 (2003) 359–369 structures, the following conclusions are drawn and recommendations are given: 1. The two alternative methods for surface stress extrapolation (as shown on the right and left side of Fig. 3) yield almost the same results. The first procedure with reference points 0.4 t / 1.0 t away from the weld toe (or 4/8/12 mm at plate edges) requires a finer mesh with element lengths of at least 0.4 t (or 4 mm, respectively), if higher-order elements are used. However, finer mesh densities are also allowed. The second procedure with reference points 0.5t /1.5 t away from the weld toe (or 5/15 mm at plate edges), which is preferred by several ship classification societies, requires fixed sizes of higher-order elements to achieve consistent results. 2. The procedure proposed by Dong [2] for the evaluation of the structural stress directly at the weld toe shows mesh-insensitivity for 2D problems. However, in the case of 3D stress concentration, some scatter is observed in the results evaluated from different mesh densities. This seems to be due to the neglect of stresses in the equilibrium equations acting at the transverse element sides. The scatter increases if the notch is very localized, as exemplified by the toe of a bracket oriented in stress direction, which is in practice often very simply modelled by using shell elements. In case of in-plane notches, i.e. at plate edges, the structural stress depends on the assumption of a crack depth, which defines the range of stress linearization. 3. Additional scatter of the stress results is expected due to the usage of different element types offered by finite element programs and due to different techniques of modelling the weld, particularly if shell elements are applied. This scatter is typically between ±5% and ±10% [6]. In addition, the investigations have shown that also the meshing outside the stress evaluation area in front of the weld toe can further affect the results, so that mesh-insensitivity remains generally questionable. The analyst should always be aware of the limitations set by the finite element model as well as by the evaluation method of the structural hot-spot stress. 4. The definition of the structural stress is principally the same in all methods, except for cases with nonmonotonic trough-thickness stress distributions (see section 2.3). Therefore, the fatigue assessment by SN curves should also be comparable. Niemi [14] recommends for welds at steel FAT 100 for normal cases and FAT 90 for cases with full-load carrying fillet welds (example 4) and side attachments longer than 100 mm. The FAT number corresponds to the characteristic fatigue strength reference value of the design S-N curve at 2 million cycles. The fatigue lives evalu- ated with the structural stress by Dong [2] seem not to be in contradiction to this. Although the examples chosen cover a variety of different types of weld toes and practical situations, they are still relatively simple. Several questions remain open, e. g. the applicability of the methods to complex, biaxial stress states or to very thick structural members, e. g. bulbs of profiles, where it is difficult to select an appropriate thickness for the definition of stress extrapolation points or for the depth for stress linearization. All the aforementioned aspects should be considered when assessing the reliability of the different methods. In addition the practicability is very important for the industrial application. Furthermore it should be noted that the fatigue prediction may strongly be affected by other influence factors such as positive (compressive) residual stresses or large variations in the local weld profile, which should be taken into account when assessing the methods. In this sense, the structural hot-spot stress approach remains to be a relatively coarse, however, very practical approach. References [1] Atztori G, Meneghetti G. 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