Geometry beats material — page 13
The row that remembers its overload
A row of twenty leaning screws reaches 98% of twenty screws' peak, once. Loaded again, a screw that has been past its peak comes back along a softer path and reaches the slip it had been to with less load than it carried there. So a row loaded again and again neither simply evens out nor simply ratchets down: below 0.965 of its first peak it settles after a few cycles with the middle screws catching up, and above it the end screws are pushed back onto their curve every cycle, lose a little more each time, and the row fails at a load it carried the first time. One large overload costs it less than many smaller ones near the peak.
The hinge squeezed while it turns
The leeward column of a frame overturning in an earthquake gains compression as its base hinge rotates. Followed fibre by fibre, with every fibre's plastic strain remembered, the hinge does neither of the things the constant-load curves suggest. It forms early, at the low load it started with, and then rides down the section's plastic moment as the load rises: an I-section whose compression goes from a tenth to six-tenths of its squash load holds 0.86 of its unloaded plastic moment at twice its first-yield curvature and 0.43 at twelve times it. The steel never softens, and the hinge still has a falling branch, set by statics. The relieved column on the other side gains what this one loses, less the curvature of the interaction curve.
The corner with one fillet
A rolled I-section's web meets its flanges in two T junctions, four fillets, and its torsion constant is 7 to 12 per cent above Σbt³/3 because of them. An angle meets itself in one L, and a channel's web meets its flanges in two. Solved over the real outline, an L junction's fillet adds about two-thirds of what a T junction's does with the same plates. The sum then errs on either side: low by 8% for an I-section with a channel's plates, high by 0.8% for the channel itself, and anywhere from 5% low to 2% high for angles, depending on which length of leg is counted. The fillet's peak stress is still the inscribed circle's, to a few per cent.
The brace that holds a mode
A shallow arch rising eight radii of gyration turns sideways at a load of 461 when its symmetric snap would not come until 844. A member that only stops the quarter points moving in opposite senses — a brace on the sideways mode, not on any one point — gives the whole difference back once it is 1.75 times as stiff as the rib's own resistance to that mode, and nothing more after that. The stiffness needed grows as the square of the rise. And the brace is not the light member the argument suggests: an arch built a tenth of a radius of gyration out of shape puts an eighth of its whole load through it at the peak.
The coupling beam asked for shear
The coupling beams of a pair of shear walls are the stubbiest members in a building, and the shear term in their deflection is largest exactly there: a beam two metres deep over a 2.4 m opening is a third as stiff as bending alone says. The walls hardly notice. The pair's degree of coupling moves by under 3%, the beams' shears by under 7%, because a beam that stiff has stopped deciding how much of the overturning the walls carry as a couple. What decides it is the shear the beams can give. A 600 mm beam limited to 2 N/mm² starts to yield at 1.9 times the storey force; past the last yield the pair is two cantilevers again, and the beams supply rotation instead.
The flanges that lean on each other
A bolted end-plate joint's stiffness is built from springs in series: the end plate as a tee stub on a rigid base, the column flange as another, the bolt shared between them. The rigid base is not a fiction. It is exactly the plane of symmetry between two identical flanges bolted back to back, so for matched flanges the series sum is exact. A real end plate and column flange are not matched, and each tip bears on a tip that moves differently from its own. Solved as a pair, the error is the mismatch: 3% for an 18 mm end plate on a 14 mm column flange with similar lever arms, 12–15% when the end plate's bolt is twice as far from its web.
The deck that cracks over the pier
Over the pier of a continuous composite bridge the concrete deck is in tension and cracks, and what is left of it is a grid of bars and struts. Shear lag does not stop at the cracks: the bars still receive their force through the concrete between them. Whether the cracked deck works over a narrower width than the whole one depends on one ratio, the deck's shear stiffness over its axial stiffness — and once the concrete has cracked, both of those come from the reinforcement, so the answer is set by how the bars are arranged.
The corner that counts its crossings
As a load crosses a Vierendeel girder, the moment at a post's corner changes sign when the load passes that post. A static check reads the peak, and the peak says the posts beside the supports work twice as hard as the middle one. Fatigue reads the range, and the range says every interior post works the same. A haunch at the corner lowers the corner's range and moves the worst of it to the haunch's toe — so a deeper haunch soon buys nothing, a longer one keeps paying, and a toe two detail categories worse than the corner cancels the haunch outright.
The root that has to stretch for it
A partial-penetration weld made from one side carries its pull off the plates' line, and counted elastically it keeps a quarter of a double-sided weld at half penetration. Let the throat yield and it keeps 0.41 — but the same 0.41 at every direction up to the one where the double-sided weld is strongest, so that weld's peak advantage is never won back. What the yielding does instead is move the single side's own strongest direction out to 40° or beyond, where a deep single-sided throat outcarries a fillet. Every per cent of it is paid for with strain at the root, which is the tip of an unfused land.
The lever that moves the damper and not the band
A damper whose force goes as a low power of its speed is sized for the earthquake and locks in the wind. A toggle or scissor linkage multiplies its stroke, and it seemed it might move the band of amplitudes the damper serves down towards the wind. It cannot. Behind a lever of ratio f the same damper acts on the storey as one f to the power 1 + α larger, so its band moves up, not down; re-sized to the design amplitude, it gives the storey exactly the curve it had without the lever, and what has changed is the damper — a quarter of the size, a third of the force, three times the stroke. What would widen the band is a ratio that grows with the motion, and a toggle has one — until its links lie straight and it locks.
The mechanism that stands up anyway
Two bars in a straight line between two pins are a mechanism by the count, by the rank and by every measure of how nearly a frame folds. Tension them and they carry load: 200 kN of tension gives the joint the stiffness of the same bars raised 1.8 degrees, and where the bars raised 3 degrees snap through at 11 kN, the tensioned flat pair carries 50 kN and goes on stiffening. The stiffness is a lack of fit of four millimetres, which 83 degrees of warmth takes away; compressed, the same pair buckles to rest crooked on one side or the other; and no tension can reach a mechanism that swings rather than shivers.
The wire that cannot push
A tube's liner wound with wire under tension is a compound tube of a hundred layers, each shrunk on by its own winding. It reaches the same ceiling, twice the first-yield pressure, and no further, because the bore's range belongs to the whole wall and its floor to the liner's steel. What the wire's strength decides is where the ceiling can be reached at all. A wire cannot be compressed, so a jacket of the liner's own steel needs a wall three times the bore, where shrunk-on layers of the same steel need 2.22; wire half as strong again needs 1.69; wire twice as strong reaches it on any wall. Every turn is wound harder than it will rest, by what all the turns after it take away.
The diaphragm that is a few angles
A box girder's diaphragm holds its section square against the distortion an eccentric load drives. It does not have to be rigid; it has to be stiff against the girder's own resistance to a point racking load, which is small — twice the section's frame stiffness times its decay length. A cross-frame of two 1,000 mm² diagonals is twenty-six times that and holds the warping stress at the rigid value, while a 10 mm plate is five hundred times it. The cross-frame lets the section rack three times as far as a plate, which leaves the walls bending at 5 N/mm² instead of 1.5, against 275 with no diaphragm at all. And its diagonals carry nearly a rigid diaphragm's force whatever their stiffness, so it is sized for strength.
The trace that adds up every storey
A column's buckling load can be bounded from below by the traces of its flexibility, with no shape guessed. A sway frame has a flexibility too — one number per pair of floors — and its traces bound the frame's critical load factor from below and from above, closing in as more are taken: on a six-storey frame whose factor is 14.96, the first four give 14.07 to 16.39. But the first trace is Dunkerley's sum over the storeys, counting each as though its sway mode were the frame's, and it bounds a well-balanced frame worst of all: one over the number of storeys when every storey is alike, which is exactly when Eurocode 3's storey-by-storey estimate is exact.
The column that shortens on every cycle
A column hinge bent back and forth by an earthquake carries its share of the building's weight the whole time. In elastic–perfectly plastic steel an I-section at three tenths of its squash load, cycled to three times its first-yield curvature each way, comes back from every cycle shorter by eight yield strains, and goes on doing so: it never settles. The flange that yields in compression shortens, and the other flange, carrying its part of the column's load, never reaches yield in tension to pull it back. A rectangle of the same area shortens a fifth as fast, and the overturning that swings the column's load up and down hardly matters. The weight and the curvature make the ratchet between them.
The braces that have to hold each other
One brace at mid-height must have a stiffness of twice the column's load over the length it halves. Spread the same column over four braces and each one must be stiffer, not softer: 3.62 times the load over its segment, rising towards four with every brace added, because the shape the braces have to stop is a zigzag in which every brace point is pushed by both its neighbours. Braces that tie the column to itself instead of to the ground need one, however many there are. A row with surplus stiffness can carry one brace at two thirds of the ideal, but not one that is missing, and the force each brace has to resist grows with the count.
The notch that costs more than its depth
Cut a timber beam's underside away at the support, so that half its depth sits on the bearing, and a stress check on what is left says the end has lost half its shear strength. The beam says otherwise. A crack starts at the notch's corner and runs along the grain, and whether it runs is a question of energy, not stress — so the answer has a size in it. A 400 mm glulam beam notched to half its depth keeps a quarter of its shear resistance, an 800 mm one keeps 18 per cent, and the deeper the beam the less a notch leaves. Sloping the notch buys much of it back, and moving the corner away from the support costs it again.
The tank that is its own tower
A standpipe holds its water in its own shaft, so the water fills a height several times its width. Only a lens of it near the surface sloshes — 0.455ρπR³, 178 t of the 2,199 t in a steel standpipe 10 m across and 30 m tall — and that lens stops growing once the water is deeper than a radius, so its period is set by the width alone: 3.3 s, against the shaft's 0.38. The lens is 8% of the water but a quarter of the shaft's moving mass, because it sits where the shaft moves most. It is far too slow to be tuned as a damper, and a screen can do little with it; what it does instead is stay still while the shaft sways, which takes nearly a fifth off the drift a frozen-water calculation predicts.
The clamp the pair holds longer
A preloaded bolt clamps an end plate to a column flange, and the joint stays closed until the tension relieves the clamp. The joint diagram says that happens at the preload over one minus the bolt's share — 122 kN for a 110 kN preload — but prying adds to the tension at the bolt line and the clamp lets go at 88. A component model checks each flange as a stub on a rigid base and lets the joint go when its weaker stub does, at 81 kN. The real pair, its tips leaning on a column flange that gives way, pries less than the end plate alone would, and holds its clamp nine per cent longer — fifteen when its lever arms are two to one.
The tank that must be shallow to be slow
A deep tank's sloshing period is set by its width alone, so a tank in a tall building's core ought to be tuned by choosing how wide to make it. It cannot be. A deep tank fast enough to fit is too fast for the building: 3.6 s for a core 10 m across, where a 5 s building would need a tank 19.5 m long and an 8 s one 50 m. The depth has to tune it, and only shallow water is slow — 1.73 m for 5 s, 0.63 m for 8. Shallow water is the efficient kind, with four fifths of it sloshing. But at the accelerations the tank exists to reduce, the wave it makes is a quarter of its depth on a 5 s building and seven tenths on an 8 s one, and the linear tuning it was designed by has stopped describing it.
The pressure that switches at the hopper
Below a silo's bin a conical hopper funnels the grain to its outlet, and the wall pressure there does not keep growing with depth as a liquid's would. It peaks at the hopper's top edge. Filling, the edge carries twice the bin wall's pressure just above it; emptying, the grain converges on the outlet, its largest stress turns from vertical towards horizontal, and the edge carries two and a half times. Half a metre above the apex the stress is 2.6 kPa whether the bin holds 5 m of grain or 60 — which is why a silo empties at the same rate full or nearly empty.
The notch that trades stress for strain
A notch with an elastic factor of three triples the stress at its root only while the root stays elastic, which in a mild steel is up to a nominal stress of about 84 N/mm². Past that the root's stress and strain part company: at a nominal 200 the root carries 293 N/mm², not 600, and strains 0.61 per cent, twice what the elastic factor implies. Neuber's rule and Glinka's bracket the truth a factor apart, and in the low-cycle range that factor is a factor of two in life. The trade has two gifts in it: one overload leaves the root in compression, and a mean stress mostly yields itself away.
The braces that pull only one way
A brace made of a single tie, or a cross-frame whose diagonals can only pull, resists a girder twisting one way and not the other. A buckling girder has no preference between the two directions, so it takes the one its braces leave free. Three such braces all facing the same way leave a 24 m girder exactly as weak as if they were not there. Facing alternately, they reach 3,087 kN·m at the stiffness that takes two-way braces to 5,627, and no stiffness takes them past 4,063. Opposing the outer pair does not help; one one-way brace anywhere in the row is enough to cap it. Every brace has to resist both ways, and made of ties that costs twice the steel.
The splice that bends as one section
A plate spliced with two unequal covers shares its load by lever arm about the line the load is held on, and the thinner cover carries more. A beam's flange splice looks like the same joint, and the rule that worked for the plate puts the thin inner covers at the edge of yield. They are working at half that. A beam's halves are not held on any line; they turn, and every splice plate across the gap turns with them, so the plates bend as one section and share the beam's moment by their distances from its neutral axis. The outer cover works hardest, the inner covers less, and the web plates less than the hand design hands them.