철도차량 차체 가스용접 이음재의 가속수명예측과 신뢰도 평가

백승엽,Baek, Seung-Yeb 대한용접접합학회 2010 대한용접·접합학회지 Vol.28 No.1

Stainless steel sheets are widely used as the structure material for the railroad cars and the commercial vehicles. These kinds structures used stainless steel sheets are commonly fabricated by using the gas welding. Gas welding is very important and useful technology in fabrication of a railroad car and vehicles structure.However fatigue strength of the gas welded joints is considerably lower than parent metal due to stress concentration at the weld, fatigue strength evaluation of gas welded joints are very important to evaluate the reliability and durability of railroad cars and to establish a criterion of long life fatigue design. In this paper, $({\Delta}{\sigma}_a)_R-N_f$ curve were obtained by fatigue tests. Using these results, the accelerated life test(ALT) was conducted. From the experimental results, an acceleration model was derived and acceleration factors are estimated. So it is intended to obtain the useful information for the fatigue lifetime of plug and ring gas welded joints and data analysis by statistic reliability method, to save time and cost, and to develop optimum accelerated life prediction plans.

CT형 점용접 이음재의 피로설계에 관한 연구

백승엽,Baek, Seung-Yeb 대한용접접합학회 2010 대한용접·접합학회지 Vol.28 No.2

Stress distribution and deformation on the CT-type(Cross Tension type) spot welded lap joint subjected to out of plane tensile load were investigated by finite element method. Using the maximum principal stresses at the nugget edge obtained by FEM analysis, evaluated the fatigue strength of the CT-type spot welded lap joints having various dimensions and materials. and also, the influence of the geometrical parameters of CT-type spot welded lap joints on stress distribution and fatigue strength must be evaluated. thus, in this paper, ${\Delta}P-N_f$ curve were obtained by fatigue tests. Using these results, ${\Delta}P-N_f$ curve were systematically rearranged in the $\Delta\sigma-N_f$ relation with the hot spot stresses at the CT-type spot welded lab joints. It was found that the proposed $\Delta\sigma-N_f$ relation could provide a more reasonable fatigue design criterion for the CT-type spot welded lap joints.

STS301L 용접종류별 이음재의 피로설계에 관한 연구

백승엽,Baek, Seung-Yeb 대한용접접합학회 2010 대한용접·접합학회지 Vol.28 No.3

Stainless steel sheets are widely used as the structural material for the railroad cars and the commercial vehicles. These kinds structures used stainless steel sheets are commonly fabricated by using the gas welding. For fatigue design of gas welded joints such as fillet and plug type joint, it is necessary to obtain design information on stress distribution at the weldment as well as fatigue strength of gas welded joints. And also, the influence of the geometrical parameters of gas welded joints on stress distribution and fatigue strength must be evaluated. the ${\Delta}P-N_f$ curves were obtained by fatigue tests. Using these results, ${\Delta}P-N_f$ curves were rearranged in the ${\Delta}{\sigma}-N_f$ relation with the maximum stress at the edge of fillet welded joint.

실험계획법을 이용한 STS301L 이음재의 GMA 용접 자동화에 관한 연구

백승엽,손일선,Baek, Seung-Yeb,Sohn, Il-Seon 대한용접접합학회 2010 대한용접·접합학회지 Vol.28 No.4

Stainless steel sheets are widely used as the structural material for the railroad cars and the commercial vehicles. These kinds structures used stainless steel sheets are commonly fabricated by using the GMAW (gas metal arc welding). For fatigue design of GMA welded joints such as fillet and plug, ring type joint, it is important to obtain optimum design factor information on GMA welded joints. in this paper, analysis approach for fatigue test using design of experiment are evaluated optimum factor in GMA welded joint type and geometrical parameters of materials. Using these results, that factors applied to fundamental information for fatigue design.

HDM을 이용한 잔류응력측정과 압축·인장 잔류응력이 인가된 재료의 피로수명평가

백승엽,Baek, Seung Yeb 대한용접접합학회 2013 대한용접·접합학회지 Vol.31 No.2

This paper Investigated the characteristics of residual stress in weld is composed of typical specimens, are investigated by using three dimensional thermal elasto-plastic FEM analysis. Numerically calculated residual stresses in the gas welds were then compared with experimental results obtained by the hole-drilling method. Using the stress amplitude (${\sigma}a$)R at the hot spot point of gas weld, the relations obtained as the fatigue test results for typical specimens having various dimensions and shapes were systematically rearranged to obtain the (${\sigma}a$)R-Nf relationship. It was found that more systematic and accurate evaluation of the fatigue strength of plug- and ring-type gas-welded joints can be achieved by using (${\sigma}a$)R.

STS 301L 필렛 용접이음재의 피로설계에 관한 연구

백승엽(Seung yeb Baek) 대한기계학회 2010 大韓機械學會論文集A Vol.34 No.5

용접부는 일반적으로 잘 알려져 있는 바와 같이, 외력에 의한 응력 집중원(stress concentration source)이 되는 것은 물론 용접과정에서의 입열(heat input)로 인한 성분과 조직의 변화에 의해 반복하중에 대한 피로강도(fatigue strength)가 모재의 그것에 비해 훨씬 떨어져서 피로균열(fatigue crack)의 발단이 되고 있다. 따라서, 본 연구에서는 실제로 철도차량에 적용되는 가스용접 이음재 가운데 대표적인 형상시편들을 재질별로 피로실험을 수행하여 피로하중범위-피로수명(ΔP-Nf) 관계를 도출하여 비교·평가하였다. 또한, 수치 해석적 유한요소법을 이용하여 용접이음재의 응력분포를 해석한 후, 용접이음부에 발생하는 최대주응력으로 (ΔP-Nf) 관계를 Δσ-Nf 관계로 재정리하였다. 이상의 결과들을 바탕으로, 가스용접이 적용된 철도차량 차체의 경제적이고 합리적인 피로설계를 위한 기초정보로 사용하고자 하였다. Stainless steel sheets are widely used as structural materials for the manufacture of railroad cars and commercial vehicles. These kinds structures used stainless steel sheets are commonly fabricated by using the gas welding. For the fatigue design of gas welded joints such as fillet joints and plug joints, it is necessary to obtain information on the stress distribution at the weldment and the fatigue strength of the gas welded joints. Moreover the influence of the geometrical parameters corresponding to the gas welded joints on the stress distribution and fatigue strength must be evaluated. ΔP-Nf curves were obtained from the data recorded in fatigue tests. Using these results, the ΔP-Nf curves were rearranged according the relation between Δσ-Nf and the maximum stress at the edge of the fillet welded joint.

STS301L 가스용접 이음재의 가속수명예측 (Ⅰ)

백승엽(Seung yeb Baek) 대한기계학회 2010 大韓機械學會論文集A Vol.34 No.4

용접이음부의 신뢰성 확보는 구조물의 건전성과 내구성에 직접적인 영향을 미치기 때문에 가스용접 이음재의 피로설계기준(fatigue design criterion)을 정하기 위해서는 피로시험을 수행하여 ΔP-Nf 관계를 이용하는 것이 일반적이다. 그러나 피로데이터를 장시간 획득하는 과정에서 여러 가지 변동인자에 의해서 피로데이터가 영향을 받기 때문에 피로데이터의 신뢰도가 떨어진다. 또한, 이음재의 재질 및 접합형태가 달라질 때마다, 각각의 경우에 대해서 새로운 피로시험이 요구됨으로 많은 시간과 비용이 소모된다. 따라서 이러한 문제점들을 개선하고 신뢰성 있는 설계를 하기위해서 필렛 가스용접 이음재를 적용, 반복피로시험을 통한 데이터를 통계적으로 분석하여, 다양한 가스용접 이음재의 피로수명을 예측함과 동시에 실제 피로시험데이터와 비교ㆍ분석하여 예측된 수명의 신뢰도(reliability)와 신뢰구간(confidence interval)을 추정함으로서 새로운 피로설계기준 방법을 제시하고자 하였다. Stainless steel sheets are widely used as the structural material for railroad cars and commercial vehicles. Structures made of stainless steel sheets are commonly fabricated by gas welding, For the fatigue design of gas welded joints such as fillet joints, it is necessary to obtain design information of the stress distribution at the weldment as well as the fatigue strength of the gas-welded joints. Further, the influence of the geometrical parameters of gas-welded joints on stress distribution and fatigue strength must be evaluated. in this study, ΔP-Nf curves were obtained by fatigue tests. and, the ΔP-Nf curves were rearranged on the basis of the Δσ-Nf relation for the hot-spot stresses at the gas-welded joints. These results, were used for conducting an accelerated life test(ALT) From the experiment results, an acceleration model was derived and factors were estimated. The objective is to obtain the information required for the analysis of the fatigue lifetime of fillet welded joints and for data analysis by the statistic reliability method to save time and cost and to develop optimum accelerated life prediction plans.

용접잔류응력을 고려한 STS301L 플러그 및 링 용접부의 피로설계 자동화에 관한 연구

백승엽(Seung yeb Baek),윤기호(Ki Ho Yun) 대한기계학회 2010 大韓機械學會論文集A Vol.34 No.9

가스용접 구조물의 장 수명 피로설계기준(fatigue design criterion)을 결정하기 위해서는 정확한 응력해석과 체계적인 피로강도평가가 필요하다. 그러나 실 구조물로부터 피로설계기준을 결정하는 것은 대단히 어려우므로 구조물의 기계적ㆍ구조적 특성을 만족하는 간편 시편을 만들어서 σ-Nf 관계를 도출하여 피로강도를 평가하고 있다. 그리고 가스용접에 의해 제작된 실 구조물의 피로설계를 위해서는 피로균열발생과 파단 기점이 되는 용접부의 용접잔류응력(welding residual stress)이 고려되어야 한다. 따라서, 본 연구에서는 플러그 및 링 가스용접 이음재에 대한 용접잔류응력을 고려하기 위해 용접 열 사이클(heat cycle)에 의한 비선형 열해석(non-linear thermal analysis)과 열 응력(thermal stress) 해석을 수행하고, 실험 치와 비교ㆍ분석하여 용접잔류응력을 고려한 응력 진폭-피로수명((σa)R-Nf) 관계를 도출하여 자동적으로 피로설계기준을 제시할 수 있도록 하고자 하였다. This paper presents a fatigue design method for plug- and ring-type gas-welded joints, which takes into account the effects of welding residual stress. To develop this method, we simulated the gas-welding process by performing nonlinear finite element analysis (FEA) To validate the FEA results, numerically calculated residual stresses in the gas welds were then compared with experimental results obtained by the hole-drilling method. To evaluate the fatigue strength of plug- and ring-type gas-welded joints influenced by welding residual stresses, the use of stress amplitude (σa)R, which includes the welding residual stress in gas welds, is proposed (σa)R on the basis of a modified Goodman equation that includes the residual stress effects. Using the stress amplitude (σa)R at the hot spot point of gas weld, the relations obtained as the fatigue test results for plug and ring type gas welded joints having various dimensions and shapes were systematically rearranged to obtain the (σa)R-Nf relationship. It was found that more systematic and accurate evaluation of the fatigue strength of plug- and ring-type gas-welded joints can be achieved by using (σa)R.

잔류응력을 고려한 압연강 용접구조물의 X-ray 회절법에 의한 파괴 역학적 고찰

백승엽(Seung yeb Baek),배동호(Dong Ho Bae) 대한기계학회 2011 大韓機械學會論文集A Vol.35 No.10

용접이음부의 신뢰성 확보는 구조물의 건전성과 내구성에 직접적인 영향을 미치기 때문에 점용접 이음재의 피로설계기준(fatigue design criterion)을 정하기 위해서는 정확한 응력해석과 체계적인 피로강도평가가 필요하다. 따라서 본 연구에서는 실제 전동차량 차체에 많이 적용되는 냉간 및 열간압연강판인 SPCC, SPCE, SPHE을 대상으로 기하학적 인자(geometrical factors)들을 선별해서 TS형과 CT형의 대표적인 점용접 이음재 시험편을 기본모델로 하여 인장전단하중을 가하여 피로강도 및 피로특성을 평가하고자 하였다. 그리고 피로균열의 발생과 성장 기구에 대한 영향을 분석하기위해 용접 시 발생되는 여러 가지 주요인자들 중 입열량에 의해 발생할 수 있는 용접잔류응력을 X-ray 회절법에 의해 실험적으로 해석하였다. 그리고 이러한 해석을 통하여 얻어진 결과를 중첩(superposition)함으로 해서 잔류응력을 고려했을 경우 너깃 단 최대주응력으로 피로강도를 재평가하여 합리적인 피로설계기준(fatigue design criterion)을 재정립하고자 하였다. Cold and hot-rolled carbon steel sheets are commonly used in railroad cars or commercial vehicles such as the automobile. The sheets used in these applications are mainly fabricated by spot welding, which is a type of electric resistance welding. However, the fatigue strength of a spot-welded joint is lower than that of the base metal because of high stress concentration at the nugget edge of the spot-welded part. In particular, the fatigue strength of the joint is influenced by not only geometrical and mechanical factors but also the welding conditions for the spot-welded joint. Therefore, there is a need for establishing a reasonable criterion for a long-life design for spot-welded structures. In this thesis, ΔP-N_f relation curves have been used to determine a long-life fatigue-design criterion for thin-sheet structures. However, as these curves vary under the influence of welding conditions, mechanical conditions, geometrical factors, etc. It is very difficult to systematically determine a fatigue-design criterion on the basis of these curves. Therefore, in order to eliminate such problems, the welding residual stresses generated during welding and the stress distributions around the weld generated by external forces were numerically and experimentally analyzed on the basis of the results, reassessed fatigue strength of gas welded joints.

TS형 박강판 용접 구조물의 자동화설계를 위한 피로특성에 관한 연구

백승엽(Baek-Seung Yeb),배동호(Bae-Dong Ho) 한국생산제조학회 2012 한국생산제조학회지 Vol.21 No.2

Cold-rolled carbon steel sheets are commonly used in railroad car or commercial vehicles such as the automobile. These are mainly fabricated by spot welding which is a kind of electric resistance welding. But fatigue strength of spot welding joint is lower than that of base metal due to high stress concentration at nugget edge of the spot welded part. And fatigue strength of them is especially influenced by not only geometrical and mechanical factors but also welding conditions of the spot welded joint. So for fatigue design of gas welded joints such as TS-type joints, it is necessary to obtain design information on stress distribution at the weldment as well as fatigue strength of spot welded joints. And also, the influence of the geometrical parameters of spot welded joints on stress distribution and fatigue strength must be evaluated. And analysis approach for fatigue test using design of experiment are evaluated optimum factor in TS-type welded joint and geometrical parameters of materials. Using these results, that factors applied to fundamental information for automation of fatigue design.