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Curved aluminium extrusions are applied in a wide range of industrial applications. Because extrusions are initially straight, an additional process is required to curve the product. Undesired wrinkling of the plate part at the inner radius is frequently observed during the curving process. Wrinkling has already been extensively studied for the rotary-draw bending process. This paper aims at predicting the conditions for which wrinkling of a hollow section can occur during the three-point-roll bending process. It is shown that the most important condition for wrinkling is that buckling of the compressed plate part at the inner radius occurs. An analytical prediction model for buckling is presented, which predicts the critical bending radius as a function of the plate slenderness. The analytical model is validated with a finite element model, which in turn is validated with an experiment. Both the finite element model and the experiment confirm that wrinkling does not occur if the applied radius exceeds the model predicted critical radius.

Many aluminium structures contain welded and bolted connections that are modeled as one or more equivalent T-stubs – also referred to as tension zone components – for the structural assessment. Knowledge on the structural behavior of such T-stubs is thus essential for proper designs. However, this behavior has never been checked for fire conditions. In this paper, the structural behavior of aluminium T-stubs exposed to fire is studied through a combination of tests, finite element simulations, and theoretical models. A safe and conservative assessment procedure is developed for determining the critical temperature, based on the material deterioration as a function of temperature. This enables engineers and practitioners to determine a conservative value of the fire resistance.

Estimating and reducing uncertainty in fatigue test data analysis is a relevant task in order to assess the reliability of a structural connection with respect to fatigue. Several statistical models have been proposed in the literature with the aim of representing the stress range vs. endurance trend of fatigue test data under constant amplitude loading and the scatter in the finite and infinite life regions. In order to estimate the safety level of the connection also the uncertainty related to the amount of information available need to be estimated using the methods provided by the theory of statistic. The Bayesian analysis is employed to reduce the uncertainty due to the often small amount of test data by introducing prior information related to the parameters of the statistical model. In this work, the inference of fatigue test data belonging to cover plated steel beams is presented. The uncertainty is estimated by making use of Bayesian and frequentist methods. The 5% quantile of the fatigue life is estimated by taking into account the uncertainty related to the sample size for both a dataset containing few samples and one containing more data. The S-N curves resulting from the application of the employed methods are compared and the effect of the reduction of uncertainty in the infinite life region is quantified.

Standards and guidelines for the fatigue design of riveted connections make use of a stress range-endurance (S-N) curve based on the net section stress range regardless of the number and the position of the rivets. Almost all tests on which S-N curves are based, are performed with a minimum number of rivets. However, the number of rivets in a row is expected to increase the fail-safe behaviour of the connection, whereas the number of rows is supposed to decrease the theoretical stress concentration at the critical locations, and hence these aspects are not considered in the S-N curves. This paper presents a numerical model predicting the fatigue life of riveted connections by performing a system reliability analysis on a double cover plated riveted butt joint. The connection is considered in three geometries, with different number of rivets in a row and different number of rows. The stress state in the connection is evaluated using a finite element model in which the friction coefficient and the clamping force in the rivets are considered in a deterministic manner. The probability of failure is evaluated for the main plate, and fatigue failure is assumed to be originating at the sides of the rivet holes, the critical locations, or hot-spots. The notch stress approach is applied to assess the fatigue life, considered to be a stochastic quantity. Unlike other system reliability models available in the literature, the evaluation of the probability of failure takes into account the stochastic dependence between the failures at each critical location modelled as a parallel system, which means considering the change of the state of stress in the connection when a ligament between two rivets fails. A sensitivity study is performed to evaluate the effect of the pretension in the rivet and the friction coefficient on the fatigue life.

PurposeSimulations exist for the prediction of the behaviour of building structural systems under fire, including two-way coupled fire-structure interaction. However, these simulations do not include detailed models of the connections, whereas these connections may impact the overall behaviour of the structure. Therefore, this paper proposes a two-scale method to include screw connections.Design/methodology/approachThe two-scale method consists of (a) a global-scale model that models the overall structural system and (b) a small-scale model to describe a screw connection. Components in the global-scale model are connected by a spring element instead of a modelled screw, and the stiffness of this spring element is predicted by the small-scale model, updated at each load step. For computational efficiency, the small-scale model uses a proprietary technique to model the behaviour of the threads, verified by simulations that model the complete thread geometry, and validated by existing pull-out experiments. For four screw failure modes, load-deformation behaviour and failure predictions of the two-scale method are verified by a detailed system model. Additionally, the two-scale method is validated for a combined load case by existing experiments, and demonstrated for different temperatures. Finally, the two-scale method is illustrated as part of a two-way coupled fire-structure simulation.FindingsIt was shown that proprietary ”threaded connection interaction” can predict thread relevant failure modes, i.e. thread failure, shank tension failure, and pull-out. For bearing, shear, tension, and pull-out failure, load-deformation behaviour and failure predictions of the two-scale method correspond with the detailed system model and Eurocode predictions. Related to combined load cases, for a variety of experiments a good correlation has been found between experimental and simulation results, however, pull-out simulations were shown to be inconsistent.Research limitations/implicationsMore research is needed before the two-scale method can be used under all conditions. This relates to the failure criteria for pull-out, combined load cases, and temperature loads.Originality/valueThe two-scale method bridges the existing very detailed small-scale screw models with present global-scale structural models, that in the best case only use springs. It shows to be insightful, for it contains a functional separation of scales, revealing their relationships, and it is computationally efficient as it allows for distributed computing. Furthermore, local small-scale non-convergence (e.g. a screw failing) can be handled without convergence problems in the global-scale structural model.

To understand sandwich panel behaviour under fire, expensive full-scale tests, or potentially more efficient fire-structure simulations can be carried out. However, these simulations have only been demonstrated to work for specific applications, either on the global scale (a fire on a simple panel) or on the small scale (a temperature load on a single screw connection), often loaded by a standard fire curve. In this paper, the quality of simulations for combined situations is investigated, i.e. a furnace fire on a set of panels including details and connections. First two existing tests are introduced, a sandwich panel façade test and a studs bolt test, followed by the presentation of their basic fire-structure simulations. In general, the heat transfer analyses agree well with the tests, whereas the structural response analyses need investigation: For the first test, out-of-plane deflections are overestimated at the beginning of the test. A parameter study indicates that this is most likely due to adhesive decomposition, resulting in face delamination and related instabilities. For the second test, the basic simulation does not show any failure, whereas the test failed by vertical bearing. However, with a two-scale model the ultimate load is estimated, and increasing vertical displacements and the onset of vertical bearing are predicted. It is concluded that future tests should include more simulation-relevant measurements. Also, global-scale models need to include features specific to the structure to be simulated, only known after tests and basic simulations, and connections may be decisive for global-scale behaviour, which can be incorporated by a two-scale model. Finally, the tests exhibited complex behaviour across different scales, and modifications and improvements of the simulations increased their fidelity. Therefore fire-structure simulations should always be verified with tests and compared with basic simulations, and modifications in the simulation models should be anticipated.

An existing constitutive model for creep, developed by Dorn and Harmathy, is modified in order to be used for fire-exposed aluminum alloys. Two alloys, 5083-O/H111 and 6060-T66, are selected for the development of this constitutive model because of their different behavior at elevated temperature and their frequent application in structures for which fire design is relevant. The material parameters in the model are calibrated with the experimental results of creep tests, carried out with constant load and temperature in time. The model is validated with so-called transient state tests, with a constant load in time (stresses ranging from 20 to 150 N/mm 2 ) and with an increasing temperature (with heating rates ranging from 1.6 °C/min to 11 °C/min and critical temperatures ranging from 170 °C to 380 °C). These tests are considered as representative for fire-exposed, insulated aluminum members. The existing constitutive model of Dorn and Harmathy provides good agreement with the transient state tests carried out for the 5xxx series alloy, but appeared to be not suited for the 6xxx series alloy. This is attributed to the early development of tertiary creep in case of 6xxx series alloys. The existing model was modified to incorporate this first stage of tertiary creep, to arrive at a good agreement between the tests and the modified model for 6xxx series alloys.

Aluminium plates containing a single hole or multiple holes in a row are recently becoming very popular among architects and consultant engineers in many constructional applications, due to their reduced weight, as well as facilitating ventilation and light penetration of the buildings. However, there are still uncertainties concerning their structural behaviour, preventing them from wider utilization. In the present paper, local buckling phenomenon of perforated aluminium plates has been studied using the finite element method. For the purposes of the research work, plates with simply supported edges in the out-of-plane direction and subjected to uniaxial compression are examined. In view of perforations, circular cut-outs and the total cut-out size has been varied between 5 and 40% of the total plate area. Moreover, different perforation patterns have been investigated, from a single, central cut-out to a more refined pattern consisting of up to 25 holes equally distributed over the plate. Regarding the material characteristics, several aluminium alloys are considered and compared to steel grade A36 on plates of different slenderness. For each case the critical (Euler) buckling load and the ultimate resistance has been determined.A study into the boundary conditions of the plate showed that the restrictions at the edges parallel to the load direction have a large influence on the critical buckling load. Restraining the top or bottom edge does not significantly influence the resistance of the plate.The results showed that the ultimate resistance of aluminium plates containing multiple holes occurs at considerably larger out-of-plane displacement as that of full plates. For very large total cut-out, a plate containing a central hole has a larger resistance than a plate with equal cut-out percentage but with multiple holes. The strength and deformation in the post-critical regime, i.e. the difference between the critical buckling load and the ultimate resistance, differs significantly for different number of holes and cut-out percentage.