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Scale changes everything — page 6

Essays 121 to 123 of 123 on this thread, in the same order.

How far a local load spreads, and what is nearest its limit. Along a steel-faced polyurethane cladding panel, 0.5 mm faces of 320 N/mm² steel on an 80 mm core crushing at 0.12 N/mm², from the middle of a strip load of 3.0 N per mm of width spread over 10 mm: the face's deflection over its value under the load, the core's compressive stress over its crushing strength, and the face's bending stress over its yield stress. The load spreads over a length set by the fourth root of the face's bending stiffness over the core's, 1/β = 20.5 mm; the deflection is 1.44 mm under the load and changes sign beyond 48 mm. The core is at 0.60 of its crushing strength and the face at 0.89 of its yield stress: this panel's face yields at 3.36 N/mm and its core crushes at 5.00.

The face that dents and the core that crushes

A sandwich panel carries bending as a couple between its faces, and that is a calculation about the whole panel. Put a local load on one face — a foot, a fixing, a dropped tool — and the face becomes a thin beam on a soft bed, spreading the load over a length the fourth root of their stiffnesses sets. Then either the face yields and dents, or the core crushes beneath it, and which comes first is decided by one thickness: below it the face gives, above it the core does, and a steel-faced roof panel is on the wrong side of it for anyone who walks on it.

A deck holds the middle of the span. The twist along an 8 m open section on forks, free to warp, carrying 12 kN/m at 75 mm from its shear centre — 900 Nmm of torque per mm of span. With nothing fastened to it the beam twists 6.25° at mid-span; a deck resisting the top flange's rotation at 5.0 kNm per metre per radian holds it to 4.20°, and one four times as stiff to 2.10°. The deck works where the beam is weakest, in the middle; near the supports the beam's own torsional stiffness does most of the work whatever is fastened to it.

Deflection

A deck is a spring, not a wall

An open-section beam loaded off its shear centre twists, and the usual reassurance is that the deck fastened to its top flange will stop it. The deck resists the flange's rotation with a stiffness per metre of span, and that stiffness has to be compared with the beam's own. On an 8 m beam a screwed deck of ordinary stiffness removes a third of the twist; on a 16 m beam the same deck removes three quarters, because the beam's torsional stiffness falls with the square of its span and the deck's does not.

Ductile until it was welded. A 2.0 m 6082-T6 member pulled in tension, as supplied and with one weld across it whose heat-affected zone is 60 mm long: the load per unit of parent section against the member's overall strain, to the maximum load, where the weaker part begins to neck. The plain member reaches 310 N/mm² at 7.0% strain, 140 mm of stretch. The welded one reaches 185 N/mm² at 0.62%, 12.3 mm — 8.8% of the plain member's, and the parent never reaches its proof stress of 260 N/mm². (uniform elongations assumed: 7.0% for the parent, 12% for the zone)

Materials

The soft zone that takes all the stretch

The metal beside a weld in heat-treated aluminium is weaker than the rest of the member and more ductile, and it is tempting to read the second fact as a consolation. It is not. A member welded across stretches only where it is weak, and the weak zone is sixty millimetres long; a two-metre 6082-T6 tie that would extend 140 mm before necking extends 12 mm once welded, and the parent metal never yields at all. What decides it is one ratio, the zone's ultimate strength over the parent's, and the ductility returns only when that ratio reaches one.

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