A probabilistic damage tolerance concept for welded joints Part 2: a supplement to the rule based S–N approach

The first part of this paper presented the required statistics and stochastic models for reliability analysis of the fatigue fracture of welded plate joints. This present Part 2 suggests a probabilistic damage tolerance supplement to the design S–N curves for welded joints. The goal is to provide the practising engineer with simple tools that predict the reliability against fatigue fracture during service life. The impact of the chosen fatigue design factors (FDF) and the uncertainty in the applied stresses is revealed. The effect of an in-service inspection programme is also predicted. The results are presented as dimensionless matrices and suggested for use in support of decision-making at the design stage, without any advanced fracture mechanics modelling and stochastic simulation. One important advantage of this format is that the probability levels are presented regardless of actual weld class and target service life (TSL). This is obtained by introducing the FDF as a key parameter to the results. This parameter is defined as the ratio of predicted fatigue life over TSL. FDF is always calculated in the S–N approach which is mandatory in fatigue life prediction. Various welded details (classes) will have the same reliability level for the same FDF. This is true at the end of TSL and at earlier stages, i.e. fractions of TSL. The absolute value of TSL is immaterial for a given FDF. In the case of in-service inspection, the inspection interval is also given without dimensions as a fraction of TSL.

Only the influence of future scheduled inspections is treated. Updating based on actual inspection results is not included as the scope of work is inspection planning at the design stage. Results for some frequent cases occurring in practice are readily derived and presented.     

Design and shared use of a terminal departure lounge for new large aircraft operations

New Large Aircraft (NLA) are new aircraft developments larger than any existing aircraft. The NLA's higher seat capacity will significantly impact passenger terminal design and operations. This paper focuses on the issues regarding the departure lounge. Deterministic queuing theory is used to determine the size and seating configuration of the lounge, as well as to decide whether a second level should be built to accommodate the increase in the number of passengers. The paper also discusses the use of the satellite section of a pier‐satellite terminal as a single lounge for the NLA. Spreadsheets are used to implement the analyses.     

洪都大桥主桥设计

洪都大桥主桥为三跨自锚式钢箱梁悬索桥,跨径布置为85m+195m+85m。该文介绍了主桥的总体布置、结构设计、设计关键技术和指导性施工顺序。     

Fatigue design for plug/ring type gas welded joints of sts301l including welding residual stresses

This paper presents a fatigue design method for plug and ring type gas welded joints, which incorporates welding residual stress effects. A non-linear finite element analysis (FEA) was first performed to simulate the gas welding process. The numerically predicted residual stresses of the gas welds were then compared to experimental results measured using a hole drilling method. In order to evaluate the fatigue strength of the plug and ring type gas welded joints, a stress amplitude (σ _a ) _R taling the welding residual stress of the gas weld into account was introduced and is based on a modified Goodman equation incorporating the effect of the residual stress. Using the stress amplitude (σ _a ) _R , the ΔP-N _f relations obtained from fatigue tests for plug and ring type gas welded joints having various dimensions and shapes were systematically rearranged into (σ _a ) _R -N _f relations. It was found that the proposed stress amplitude (σ _a ) _R could provide a systematic and reasonable fatigue design criterion for the plug and ring type gas welded joints.     

Ergonomic and biomechnical analysis of automotive general assembly using XML and digital human models

Automotive general assembly requires many manual assembly operations to be carried out by human workers. Ergonomic analysis is an important part of the design and evaluation of products, jobs, tools, machines and environments for safe, comfortable and effective human functioning. Most recent researches have involved the evaluation of working conditions to prevent work-related musculoskeletal disorders. The majority of previous research on automotive companies has mainly considered the results of ergonomic analyses such as RULA (Rapid Upper Limb Assessment), REBA (Rapid Entire Body Assessment) and OWAS (Ovako Working Posture Analysis System). Analysis of static posture including reachability, clearances for arm, hand and tool has also been used to evaluate working conditions. However, in addition to static posture analysis, a biomechanical analysis in dynamic conditions should also be conducted. There are no integrated frameworks or standard schema for ergonomic analysis using digital human models in digital environments. The purpose of this paper is to propose a new framework for the evaluation of working conditions by ergonomic and biomechanical analysis using digital models based on XML standard schema, including: products, processes, manufacturing resources and human workers. This paper presents the analysis results using the proposed framework for automotive general assembly operations. We propose a new framework for the evaluation of the assembly operations and their environments. Then we apply a digital human model to the dynamic simulation of general automotive assembly operations based on standard schemas in XML and PPRH (Product, Process, Resource and Human). Using PPRH information based on a standard XML schema to analyze the ergonomic and biomechanical results, the engineer can visualize, analyze and improve assembly operations and working environments in automotive general assembly shops using digital models.     

Prediction of fatigue life and estimation of its reliability on the parts of an air suspension system

Air suspension systems have been implemented in various commercial vehicles, such as buses and special purpose trucks, because of the comfortable ride and easy height control. An evaluation of the durability of vehicle parts has been required for service life and safety starting in the early stages of design. The cyclic load applied to the vehicle can cause fatigue failure of parts, such as the suspension frame. This paper presents a method to predict the fatigue life of the suspension frame at the design stage of the air suspension system used in a heavy-duty vehicle. To estimate the fatigue life using the SN method, the Dynamic Stress Time History (DSTH) is necessary for the part of interest. DSTH can be obtained from the results of the flexible body dynamic analysis using the Belgian road simulation and the Modal Stress Recovery (MSR) method. Furthermore, the reliability of the predicted fatigue life can be evaluated by considering the variations in material properties. The probability and distribution of the expected life cycle can be obtained using experimental design with a minimum number of simulations. The advantage of using statistical methods to evaluate the life cycle is the ability to predict replacement time and the probability of failure of mass-produced parts. This paper proposes a rapid and simple method that can be effectively applied to the design of vehicle parts.     

Auto-ignition and micro-explosion behaviors of droplet arrays of water-in-fuel emulsion

The characteristics of auto-ignition and micro-explosion behaviors of one-dimensional arrays of fuel droplets suspended in a chamber with high surrounding temperature were investigated experimentally with various droplet spacings, numbers of droplet and surrounding temperatures. The fuels used were pure n-decane and emulsified n-decane with varied water contents ranging from 10 to 30%. All experiments were performed under atmospheric conditions with high surrounding temperatures. An imaging technique using a high-speed camera was adopted to measure ignition delay, flame lifetime, and flame spread speed. The camera was also used to observe micro-explosion behaviors. As the droplet array spacing increased, the ignition delay also increased, regardless of water content. However, the lifetime of the droplet array decreased as the droplet spacing increased. The micro-explosion starting time remained unchanged regardless of the number of the droplets or the droplet spacing; however, it tended to be delayed slightly as the water percentage and droplet spacing increased.     

Simulation of city bus performance based on actual urban driving cycle in China

This paper establishes the simulation model of a city bus on the basis of the EQ6110 bus prototype and its experimental data. According to the actual urban driving cycle, the fuel economy and the traction performance of the EQ6110 city bus have been simulated, and factors such as the driving cycle, the loss of power to engine accessories, the gear-shifting strategy, the fuel shut-off strategy of the engine, etc., which influence on the bus’s fuel economy, are also quantitatively analyzed. Some conclusions are drawn as follows: (1) driving cycles have a great influence on the fuel economy of a city bus; (2) under the typical urban driving cycle of the public bus in China, the engine fuel shut-off strategy can save about 1 to 1.5 percent of the fuel consumption; and (3) the optimized gear-shifting rules can save 6.7 percent of the fuel consumption. Experimental results verify that the fuel economy for the EQ6110 public bus is improved by 7.2 pecent over the actual Wuhan urban driving cycle of the current public bus in China.     

Effect on friction of engine oil seal with engine oil viscosity

Low viscosity engine oil can improve a vehicle’s fuel economy by decreasing the friction between the engine components. Frictional torque varies with the velocity change due to different viscosity characteristics of SAE grade 5W-20, 5W-30 and 5W-40 engine oils. The viscosity for each of these grades was measured to outline the effect low viscosity engine oils have on engine friction, which may lead to improved fuel economy. Engine oil seal frictional torque increases with the shaft rotational speed for all three engine oil grades. A decrease in engine oil seal frictional torque was confirmed when low viscosity engine oil was used. Also, the leak-free performance of the engine oil with the seal satisfied the life limit durability test criteria. Thus, low viscosity engine oil may be used to improve fuel economy by decreasing the frictional loss of the engine oil seal while having no negative impact on performance due to leak-free functioning.     

Lane-following method for high speed autonomous vehicles

This paper presents a steering control method for lane-following in a vehicle using an image sensor. With each image frame acquired from the sensor, the steering control method determines target position and direction, and constructs a travel path from the current position to the target position either as an Arc-path or S-path. The steering angle is calculated from the travel path thus generated, and the vehicle follows the travel path via motor-control. The method was tested using a vehicle dubbed as KAV (Korea Autonomous Vehicle) along an expressway (Seoul Inner Beltway) trajectory with a variety of radii (50 m ∼ 300 m) while traveling at a speed of 60 km/h to 80 km/h. Compared with an experienced human driver, the method showed little much difference in performance in terms of lane-center deviation. The proposed method is currently employed for high speed autonomous driving as well as for stop and go traffic.