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Geometry beats material — page 8

Essays 169 to 192 of 329 on this thread, in the same order.

The stiffness that belongs to the span

A section's flexural rigidity is a property of the section, and a member's is not. Once shear deformation is counted the effective stiffness contains the span, so the same panel is a different member at three metres and at six — and for a sandwich the correction is not a correction.

Yielding one way makes it easier to yield the other. Mild steel taken to a strain of 1.20% and then pushed back the other way. The stress falls by 550 N/mm² before it yields again, against a yield stress of 275 — the elastic range is twice the yield stress and not once it, which is the Bauschinger effect and is a consequence of the yield surface sliding rather than growing.

Materials

Yielding one way, and then the other

A material that has yielded in tension yields earlier in compression than it did the first time, and by an amount that is exactly what makes its elastic range twice its yield stress rather than once it. That is a property no monotonic test reports and every reversing structure depends on.

Prying against flange thickness. The ratio of bolt force to applied force, for a tee stub carrying 140 kN per bolt, as the flange thickness varies. Prying disappears above 31.91 mm and the flange has become a mechanism below 22.75 mm, where the shaded region begins and the bolt has stopped being the thing that decides.

Connections

The thickness that decides who fails

A bolt in a tee stub carries more than the load applied to it, because the flange bends and levers against its own edge. How much more, and whether the bolt or the flange is the thing that gives way, are both decided by one dimension — and the two regimes it separates fail in completely different ways.

A preloaded joint, before and after it slips. Four preloaded bolts at 172 kN each, on one friction face at μ = 0.5. The joint carries 344 kN by friction with the bolts in tension and not in shear at all; past that it slips into bearing and carries 362 kN with the bolts now in shear. Two different mechanisms, one joint.

Connections

The hole made bigger so the steel would fit

A preloaded joint carries load by friction, and the friction is reduced by the shape of the hole the bolt passes through — not by how much steel the hole removes, but by a coefficient in a table. An oversize hole costs fifteen per cent of the resistance; a long slot costs thirty-seven. Both are provided because the steel would not otherwise line up.

Block shear: the metal between the holes. Three bolts in a 9 mm plate end connection. The shaded block tears out along a shear plane 180 mm long and a tension plane 55 mm long. Shear ruptures first, and the capacity is the sum of two different strengths on two different planes: 524.79 kN, of which the shear plane carries 63.03%.

Connections

The end that is only a plate

Cut one flange off a beam's end and what is left is a tee. Cut both and what is left is a plate with holes in it — no flanges, no section modulus worth the name, and none of the checks the beam was selected by. Three plate checks replace them, and the one that governs depends on dimensions that appear in no section table.

A check made on a perimeter, not on a section. One bay of a flat slab, 7.2 m square, on a 400 × 400 mm column. The heavy closed line is the control perimeter, 2d from the column face with its corners rounded at that radius — 4427 mm long against 1600 mm round the column itself. The shaded area inside it delivers no shear across it and is subtracted from the load; everything outside arrives through the perimeter. At 12 kN/m² that is 604 kN across 4427 × 225 mm, a shear stress of 0.697 N/mm² against a resistance of 0.658.

Internal forces

Turn the column, and the slab passes

A flat slab that is comfortable under gravity fails its punching check the moment a moment arrives at the column, and nothing about the load has changed. The fix is not more concrete. It is the column's plan shape and, at equal area, which way round it is turned — worth more than adding half again as much column.

A built-up column has a second way to bend. A 24 m column of two chords 800 mm apart, joined by single lacing. On the left it buckles the way a solid column does, by bending; on the right the chords stay straight and the lattice racks, which a solid column cannot do at all. Neither happens alone, and the two flexibilities add rather than the two stiffnesses — so the critical load is 3832 kN against an Euler load of 4629 kN, which is 83% of it, and the column behaves as though its slenderness were 66 rather than 60.

Stability

The lacing decides the force it has to carry

A perfectly straight column carries no shear, so the diagonals of a built-up column are resisting a force that exists only because the column is crooked. Computing it turns out to be circular — the shear is amplified by the very flexibility the lacing supplies — and the rule of thumb that replaces the calculation is wrong by a factor that grows as the lacing gets worse.

The worst force in a pile is not at the top of it. A 0.75 m pile 30 m long through ground that is settling, carrying 1200 kN at its head. Above the neutral plane the soil moves down past the shaft and the friction acts downward, so the axial force grows with depth; below it the friction acts upward in the ordinary way and the force falls again to the 600 kN the base takes. The maximum is 2331.39 kN at 18.86 m — 1.94 times the load applied, and it is at a depth where nothing is applied, nothing is connected and nothing can be inspected. A pile section chosen for the head load is under-sized by that factor over the middle third of its length.

Internal forces

The coating that takes the resistance with it

The cure for downdrag is to make the pile slippery, and it works — a bitumen slip layer takes the drag on this pile from 1,131 kN to 34. It also removes the shaft friction that was holding the pile up, in the same proportion and over the same length, and past a certain smoothness there is no neutral plane to find because there is no equilibrium.

Cut the throat, and the face carries a moment and a tension at once. A crane hook of trapezoid section, 50 to 120 mm radius and 40 to 15 mm wide, carrying 100 kN, drawn beside the section at the cut and the stress across it. The load hangs on a line through the centre of curvature, so cutting the throat and taking everything below the cut as the free body leaves a face carrying a direct tension of 100 kN and a moment of N·R = 7.970 kN·m about the section's own centroid, which sits a full R = 79.70 mm from the load line. The stress is a hyperbola, zero at r = 75.04 mm rather than at the centroid 4.65 mm outside it, reaching 497.5 N/mm² of tension at the inner fibre and 281.3 of compression at the outer. The straight-beam formula, drawn dashed, reports 323.4 N/mm² for the bending part against the true 445.5, and leaves the 51.9 N/mm² of direct tension out altogether — between them, 54% under the real peak, at the fibre where a hook actually breaks. This is why a hook is trapezoidal: both effects are worst inside, so the material goes there.

Sections and stress

The wide side goes inside

A crane hook's section is a trapezoid with its broad face towards the centre of curvature, and that is not a casting convenience. Turn the same section round — same area, same depth, same moment — and the stress at the fibre that breaks rises by thirty-nine per cent. The shape is doing two things at once, and only one of them is in a straight beam's arithmetic.

The shear goes round the corner instead of across it. A 6-panel Vierendeel girder, 21 m by 6000 mm, under 300 kN at mid-span. There is no diagonal in it, so each panel's 150 kN of shear is carried as bending in the chords: the curves drawn along them are the chord moments, and every one passes through zero at the middle of its own panel. The local moment is the panel shear times the panel length over four, 131.3 kNm, and it adds to an axial force of 263 kN from the global moment at the same point. The girder deflects 109.09 mm against 6.53 mm for the same members triangulated — 16.70 times — and 98% of that movement is chord bending that a diagonal would have removed entirely.

Structural form

The frame is a girder stood on end

Every unbraced building frame is a Vierendeel girder turned through ninety degrees, and the identification is not an analogy — it is the same equations with the axes swapped. Which means the frame inherits results that read as absurd for a building — more bays is stiffer, a wider building is not, and doubling one section property halves the sway.

$A buckled panel is a truss that nobody drew. A 1500 × 2000 panel of 8 mm web, at d/t = 188. It buckles in shear at 41.0 N/mm², which is 492 kN — and it then carries 1187 kN, 2.41 times as much, because the tension diagonal takes over from the compression one that has gone. The band runs at 18.5° with a membrane stress of 348 N/mm² over a width of 788 mm, and it pulls on the flange at 280.2 N per millimetre of its length. A web that never buckled at all would have reached 2460 kN, so the panel ends at 48% of a stocky web's capacity on a fraction of its steel.$ Stability

The tension has to pull on something

A buckled web carries its shear on a diagonal band of membrane tension, and the band pulls sideways on the flanges and stiffeners that bound it. That pull is the design output nobody plots — it runs from 72 to 603 newtons per millimetre across ordinary panel proportions, it is largest exactly where the panel is most efficient, and at the end of the girder there is nothing beyond to take it.

The distortion runs the length of the span, and a diaphragm stops it. Longitudinal stress at a corner of the box from distortional warping, along a 60 m span carrying 45 N/mm at 2.0 m off the axis. With no interior diaphragm it peaks at 73 N/mm², which is 83 per cent of the bending stress the girder was designed for. Two interior diaphragms take it to 18. The governing length is Winkler's: the distortion decays over 23.6 m, so a diaphragm helps its neighbours only if it is closer than that, and past it the spacing stops mattering.

Sections and stress

One diaphragm is nearly none

A box girder's distortion decays over a length the section decides, and on a sixty-metre span that length is twenty-four metres. So a single diaphragm at midspan sits further from each end than the distortion can reach and removes a third of the problem; three diaphragms remove nine tenths. The spacing rule is not span over five — it is a property of the plates.

What a torsional brace buys, and the stiffness it takes. The critical moment of an 8 m beam against the stiffness of a single rotational restraint at midspan — a cross-frame or a stiffened connection to a secondary beam, resisting the twist rather than the sideways movement. It climbs from an unbraced 143 kNm to the same two-half-wave plateau of 447 a lateral brace reaches, and gets to 99% of it at 253 kNm/rad. Nothing in the calculation refers to a height, which is the difference that matters: a torsional brace cannot be put on the wrong flange because it is not attached to a flange in the sense the lateral one is.

Stability

Twice the moment, four times the brace

A lateral brace has to be on the right flange and its demand is very nearly linear in the load. A torsional brace has no flange to be wrong about, and its demand is exactly quadratic — so the restraint that is indifferent to where it is attached is the one that gets expensive fastest.

The stub column a bearing stiffener makes, in plan. A plan through the girder at the bearing. The 8 mm web runs across; the pair of 100 × 12 stiffeners stands off it; and the shaded strip of web either side — 15ε t_w, or 98 mm each way — is the width that buckles with the stiffeners rather than independently of them. Together they are an area of 3962 mm² with a second moment of 9.01·10⁶ mm⁴ about the web's centreline, a radius of gyration of 48 mm over a buckling length of 900 mm — 0.75 of the depth, because the flanges hold the ends. That is a slenderness of 0.25, at which the column curve returns 0.98: the stub column reaches 98 per cent of its squash load, and the section's own strength is very nearly the whole answer.

Stability

A column nine hundred millimetres long

The patch-load check asks how much of a web a flange can spread a wheel over, and answers in a plate-buckling reduction that throws seven tenths of it away. A pair of stiffeners does not improve that answer. It replaces the question with a different one, from a different family, with a different failure in it.

The curve the machine drew and the curve the material was on. The same tensile test twice. Force over the ORIGINAL area against extension over the original length is the engineering curve, which peaks at 431 MPa and 24.6 per cent and then falls. Force over the ACTUAL area against the natural logarithm of the length ratio is the true curve, which passes 538 MPa at the same instant and keeps rising. Nothing softens anywhere on this figure: the descending branch is the original area still being divided by, and the material is hardening the whole way. The two separate at the very first plastic strain and the gap between them is exactly e^ε, which is 1.25 at the ultimate load. Past that instant the deformation stops being uniform, so the engineering curve is drawn dashed: the real one falls faster than this, because the extension is now happening in one short length of the bar and the strain axis is still dividing it by the whole gauge.

Materials

The curve was rising the whole time

Every tensile curve ever printed turns over and falls, and nothing about the material does. The fall is the original area still being divided by after the specimen has stopped having it — and correcting the two denominators turns a strength, a ductility and a failure into one exponent.

The fire is one curve, and the steel in it is several. Gas temperature and steel temperature against time in a standard fire. The gas curve is the same for every member in the compartment; the three bare steel curves are section factors of 76, 160 and 323 per metre, and they reach 558 °C at 17, 11, 8 minutes — a spread of a factor of two from geometry alone. The fourth curve is the middle section with 15 mm of board on it, which reaches the same temperature at 46 minutes. The kink near 735 °C on the bare curves is not a numerical artefact: steel's specific heat spikes there as its crystal structure changes, and the member spends several minutes absorbing heat at almost constant temperature.

Materials

The temperature is a shape

Two members of the same steel in the same compartment, under the same fire and the same load ratio, fail eight minutes apart. Nothing about the material differs and nothing about the fire does. What differs is a perimeter divided by an area, and it is the only number in the whole calculation that a designer chooses.

The four corners of an opening, on the tee's own interaction diagram. The plastic interaction of the tee left above and below a 400 × 300 mm opening — every point on it computed by sweeping the plastic neutral axis through the section rather than from an interaction formula. Its squash load is 1519 kN and its plastic moment 32.2 kNm. At the working load the global moment puts 301 kN into each tee — compression above the hole, tension below — and the shear puts the same Vierendeel moment of 6.3 kNm into all four corners. The line is the path the demand takes as the load rises, and it reaches the surface at a load factor of 3.89 against 1.49 for first yield at one corner: the elastic check is finding one corner and the mechanism needs all four.

Sections and stress

Four corners and a mechanism

The check on a hole in a web adds an axial stress to a local bending stress and compares the sum with the yield stress at one corner. What ends the opening is four hinges arriving together — and the gap between the two is a factor that varies along the span from two and a half to exactly one.

Two webs of one box, carrying different amounts of the same load. The equivalent stress on each web of a 3.0 × 2.0 m box along the half span, under 40 N/mm at an eccentricity of 1500 mm, with the bending stress alone drawn for comparison. The two webs carry the same bending and opposite torsion, so one gets the sum and the other the difference: at the quarter point the loaded web is at 116 N/mm² and the far web at 11, a ratio of 10.9. A check made on the section rather than on the wall reports the average of two numbers that differ by that much.

Sections and stress

Three actions on one web

A load applied off the centreline of a box girder is three actions at once, and every textbook decomposes it into them. What the decomposition does not say is that all three land on the same piece of plate — added on one web and subtracted on the other, so the two walls of one section differ by a factor of ten.

The worst section of a haunched rafter is inside the haunch. Utilisation along a 15.3 m portal rafter carrying 8 kN/m, with an eaves moment of 500 kNm and an apex moment of 150, haunched over 3 m from 906 mm deep down to the rafter's own 453. The moment is largest at the eaves and the depth is largest there too, so the eaves is at 0.42; the apex is at 0.31. The peak is 0.46 at 2.98 m — the haunch tip, where the section has just become the bare rafter and the moment is still 226 kNm. The dashed curve is the same rafter with no haunch, which reaches 1.02 and does not pass.

Sections and stress

The section that governs is inside the haunch

A tapered cantilever has its worst section somewhere along it because the moment grows linearly and the modulus quadratically. A haunched rafter has the same competition with a step in it, and the step is where the check lands — at neither end of the member, at a station no formula names.

What a damper at the anchorage can do, and the ceiling it cannot pass. Modal damping against damper size for a 200 m stay at 4500 kN, with the damper 4 m from the anchorage — 2.0 per cent of the length. Each curve is a mode, found as a complex root of the taut string with a viscous damper in it rather than from a formula. Every one of them peaks at 1.00 per cent of critical, which is x/2L exactly, and the peaks are at different damper sizes — a higher mode wants a smaller damper, because it moves faster at the same amplitude. The curves are flat near their peaks: half the optimum coefficient gives 80 per cent of the ceiling, and so does twice it.

Dynamics

The damper that is too near the end

A stay cable has almost no damping of its own, so it is given a damper — and the damper cannot go where the motion is, because the middle of a two-hundred-metre stay is a hundred metres above the road. What it can supply is then decided by one length, and no amount of damper changes it.

The same bridge by the two theories it might have been designed by. Deck moment along a 500 m suspended span with half of it loaded, computed twice. Elastic theory treats the deck as a beam and applies the cable's extra tension as an upward load: 80.1 MN·m. Deflection theory keeps the cable's total tension acting on the deck's own deflected shape — a geometric stiffness — and returns 56.3, which is 30 per cent less. The extra cable tension is very nearly the same in both (6.20 against 6.11 MN), so nothing about the cable is in the difference: it is entirely the H·v″ term the older theory drops.

Structural form

The tension that was left out

A suspension bridge's deck sits on a cable pulling hard along it, and a member with a large tension in it is stiffened by that tension. Leaving the term out of the deck's own equilibrium is what elastic theory does, and on a long span it asks for fourteen times the girder.

What the second, third and fourth arms are worth. Top drift removed against the number of outriggers, each arrangement at its own optimum levels, on a 40-storey core 200 m tall. One arm at 59 per cent of the height removes 82.3 per cent of the drift. A second, with both moved to 35 and 71, takes it to 91.6 — a gain of 9.3 points, which is half of what was left. The third is worth 3.0 and the fourth 1.5, and each one costs a storey of the building's most valuable height.

Structural form

What the second arm is worth

One outrigger at its best height removes five sixths of a tall core's drift, which sounds like the end of the argument. A second removes half of what is left, a third half of that, and each of them costs a storey of the most valuable floor area in the building — so the question is not where to put an outrigger but how many the arithmetic still justifies.

The part of a base plate that is delivering anything. A plan of the plate: the 260 × 260 column in the middle, and the shaded region it can reach — its own outline grown by 43 mm, which is t√(f_y/3f_jd) for a 20 mm plate on grout at 20 N/mm². That is 78176 mm² of a 200000 mm² plate, or 39 per cent of it. The corners are outside it and are carrying nothing: a plate cantilevers from the column's perimeter and runs out of bending capacity at c, so making it larger in plan beyond that changes nothing at all, and making it thicker changes everything.

Connections

The plate that is only as big as it is thick

A base plate's design is presented as a bearing calculation: an area, a bearing strength, and a check that the pressure fits. The area in that calculation is the plate, and the plate cannot deliver it — a 20 mm plate on a 500 square reaches 43 mm past the column and the corners carry nothing at all.

Force and capacity round a weld group, which do not vary together. Utilisation round the c shape group under 100 kN at 150 mm, walked from one end of the weld to the other, with the force scaled onto the same axis for comparison. The capacity is 1460 N/mm where the force runs along the weld and 1789 where it runs across it — √1.5 more — so the utilisation is not simply the force in different units. The worst point is at 47 degrees to the weld, where the capacity is 1612 N/mm, and the group carries 182 kN against the 165 the along-the-weld value would allow.

Connections

The weld that is stronger where it is pulled

A fillet weld pulled across its axis is √1.5 stronger than the same weld pulled along it. On a group under an eccentric load the direction of the pull varies from point to point, so the capacity does too — and the gain that follows is worth twenty per cent at one eccentricity and nothing at all at another.

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