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Geometry beats material — page 6

Essays 121 to 126 of 126 on this thread, in the same order.

Two drawings of one deck, and they are not the same structure. A 112 m viaduct on five supports, articulated two ways. Above, the fixed point is at the left abutment: the far end has to be given 45 mm of movement, and the friction of every sliding bearing runs one way, so the fixed support takes 660 kN before any wind or braking is applied. Below, the fixed point is at the middle pier: the largest joint halves to 22 mm and the friction now cancels across the fixed point, leaving 0 kN. The movement arrows are drawn at 900 times the scale of the deck, because a 45 mm movement on a 112 m span is thinner than the line the deck is drawn with. Nothing about the deck, the loads or the ground has changed between the two.

Where the structure is allowed to move

One drawing decides how big every movement joint on a bridge is and where every horizontal force goes, it takes an afternoon, and it appears on no calculation sheet. Move the fixed point from an abutment to the middle pier and the largest joint halves and the horizontal force on that support drops from the whole of the friction to none of it.

A transverse load with nothing applied. Web slenderness against web thickness, with the limit the flange's own curvature sets. A flange carrying 6213 kN and curved to a radius of 592 m needs 10.5 N per millimetre of radial force to stay on its curve, and the only thing available to supply it is the web. Nothing has been applied to the girder: the load comes from the deflected shape, which is why a straight beam has none of it and a beam at a plastic hinge has a great deal. Setting the radial force against the web's own plate-buckling resistance gives, in four lines, h_w/t_w ≤ k·(E/f_yf)·√(A_w/A_fc) — the form the codes use, arrived at without them. The constants differ: an elastic flange strain gives k = 1.34 and the rule uses 0.3, a factor of 4.5, and the gap is the curvature assumed. k goes as the inverse square root of the flange strain, so 0.3 is a flange strained to 3.4% — which is what a plastic hinge does to it. The rule is not conservative; it is written about a different beam.

Stability

The web that is crushed from inside

A plate girder's compression flange is curved by the beam's own deflection, and a curved force needs a transverse load to stay on its curve. The only thing available to supply it is the web. So a deep girder can buckle its web vertically with nothing applied to it at all, and the rule that prevents it is the only clause in the codes about a load no load case contains.

$Ten decades of time for forty per cent of the strength. Strength as a fraction of the five-minute test value, against the length of time the load is held, over 12 decades of seconds. The relation is a straight line on this axis, which is the reason a single duration factor works at all: every decade of time costs about the same amount of strength. A load held for 60 years leaves 59% of the short-term strength, and the member need not have moved — this is not creep, and it is not fatigue, because nothing about the load varies. It is that a static stress slowly breaks fibres. The curve has an asymptote at 18% that nobody quotes: below about a fifth of its short-term strength a member has no time to failure at all, so there is a stress under which duration stops being a question rather than merely becoming a small one.$ Materials

The load that was left on too long

A timber beam that carries a load for fifty years fails at about fifty-nine per cent of the stress the same beam carries for five minutes in a testing machine. Nothing about the load varies, the member need not have deflected, and the relation between the two is a straight line on a logarithmic time axis over ten decades.

The strength was bought in a furnace and the welder gives it back. Proof stress as delivered and beside a weld, for four aluminium alloys. The heat-treated alloys lose half of it: the strength of a 6xxx extrusion is in precipitates formed by an ageing treatment, and the arc dissolves them for 32 mm either side of the weld, permanently. The work-hardened tempers lose nearly as much, because the heat undoes exactly the work. The annealed ones lose nothing at all, because there is nothing left in them to anneal. The consequence is the crossover: 5083-H22 is 1.04 times 6061-T6 as delivered and 0.92 times it once welded, so the stronger alloy is the weaker member. The 240 mm member drawn, with two longitudinal welds, keeps 87% of its parent capacity — a weld along a member softens a strip and leaves a section, and the same weld across it softens the whole of one.

Materials

The strength the welder gives back

A 6082-T6 extrusion is twice as strong as a 5083-H111 plate and, welded across, the two are within a few per cent of each other. The heat of the arc anneals the metal for thirty millimetres either side, permanently, and the strength that was bought in a furnace is given back at the first joint.

Connections

The detail decides and the steel does not

A fatigue check contains no material strength anywhere. The same detail in a steel twice as strong lies on exactly the same line, because a fatigue life is decided by the geometry of a weld and by the stress range it sees — and two per cent of the traffic does most of the damage, because life goes as the inverse cube of the range.

A restoring moment that gets smaller the further it leans. Restoring moment against rotation for a block 0.90 m wide and 4.20 m tall, both normalised — the moment by its value at first uplift, the rotation by the angle α = 12.1° at which the block topples. It is mgR·sin(α − θ), which is a weight times a geometry with no material property in it at all, and it has two features an elastic system does not. There is a jump at the origin: the moment is whatever the ground demands until uplift and then it is mgR sinα, so the law is discontinuous where a spring's is steepest. And the slope is negative — the further it leans the less it pushes back — so the equilibrium at θ = 0 is stable only because of that jump, and there is no stiffness to divide into a mass. The straight line is what a spring of the same first-uplift strength would have done.

Dynamics

The block that is safer for being bigger

A block resting on the ground lifts off at an acceleration that depends only on its shape and not at all on its size, and then falls over at one that depends strongly on its size. Two objects of identical proportion begin rocking at the same instant and only the smaller one topples — which is why the slender water towers stood in Chile and the squat tanks beside them did not.

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