Numerical investigations of stress concentration in reinforcement steel structure by composite overlays

The stress concentration observed in the vicinity of cut-outs and holes in structural elements significantly influences the fatigue endurance of machines subjected to cyclic loads. Numerous studies have been made so far to improve this situation and increase the structure lifetime. Several design recommendations have also been worked out to avoid the problem of premature failure. The proposed article illustrates the influence of the composite overlays applied around the cut-outs made in flat steel constructional elements subjected to axial tension. The detailed study concerns the reinforcement made from the FRP (fibre reinforcement polymer) composite applied around the notches. Two types of composite materials were used, namely: TVR 380 M12/R-glass (glass fibres embedded in epoxy resin matrix) and AS4D/9310 (carbon fibres embedded in epoxy resin matrix). In the first step, the detailed numerical studies (finite element analysis) were performed for the steel samples (with no overlays added) with cut-outs made in the form of circle, square and triangle hole (the last two with rounded corners). The results of these studies were compared with the existing analytical solutions with respect to the stress concentration factors (SCF) estimation. The relatively good conformity was observed when using dense meshes of finite elements placed around the void vicinity. In the next step, the composite overlays were applied around cut-outs and their influence on the stress concentration was investigated. The influence of the fibre orientation, numbers of layers, sizes of the composite overlay used were considered. It was proved that the application of composite overlays evidently decreases the stress concentration around the notches

Application of DIC Method in the Analysis of Stress Concentration and Plastic Zone Development Problems

The paper presents the assessment of the possibility and reliability of the digital image correlation (DIC) system for engineering and scientific purposes. The studies were performed with the use of samples made of the three different materials—mild S235JR + N steel, microalloyed fine-grain S355MC steel, and high strength 41Cr4 steel subjected to different heat-treatment. The DIC studies were focused on determinations of dangerous zones with large stress concentrations, plastic deformation growth, and prediction of the failure zone. Experimental tests were carried out for samples with different notches (circular, square, and triangular openings). With the use of the DIC system and microstructure analyses, the influence of different factors (laser cutting, heat treatment, material type, notch shape, and manufacturing quality) on the material behavior were studied. For all studied cases, the stress concentration factors (SCF) were estimated with the use of the analytical formulation and the finite element analysis. It was observed that the theoretical models for calculations of the influence of the typical notches may result in not proper values of SCFs. Finally, the selected results of the total strain distributions were compared with FEM results, and good agreement was observed. All these allow the authors to conclude that the application of DIC with a common digital camera can be effectively applied for the analysis of the evolution of plastic zones and the damage detection for mild high-strength steels, as well as those normalized and quenched and tempered at higher temperatures

Static and Fatigue Behaviour of Double-Lap Adhesive Joints and Notched Metal Samples Reinforced by Composite Overlays

The use of composite overlays to increase the fatigue life of notched steel samples is discussed in this paper. For such purposes, in the first set of studies, static and fatigue tests as well as the detailed analytical and numerical analyses for samples with double-lap joints were performed. Based on such studies, the shapes of the composite overlays were set. For a better understanding of the failure forms of the investigated adhesive joints, the experimental studies were monitored with the use of digital image correlation. In the second set of experimental studies, the static and fatigue tensile tests were performed for steel samples with a rectangular opening with rounded corners reinforced by composite overlays. The different shapes (square 45 × 45 mm and long stripes 180 × 15 mm) and composite materials (GFRP and CFRP) were used as overlays. The obtained improvement of fatigue life was in the range of 180–270% in the case of the rectangular overlays and 710% in the case of application of the overlays in the form of the long stripes. This was also confirmed by numerical analyses in which a reduction in the stress concentration factor from 2.508 (bare sample) through 2.014–2.183 (square 45 × 45 mm overlays) to 1.366 (overlays in the form of long stripes 180 × 15 mm) was observed

Analysis of the Efficiency of a Batch Boiler and Emissions of Harmful Substances during Combustion of Various Types of Wood

In the paper, the authors focused on the environmental problems of pollution emissions caused by households using batch boilers fired with solid fuels. The aim of this study is to analyse the course of changes in the actual efficiency and emission of a solid fuel updraft boiler, the most popular type of batch boilers used in Poland in recent years. The subject of analysis is the comparison of the values of atmospheric emissions of harmful substances depending on the type of wood burnt in the boiler. The investigation comprises the combustion characteristics of three types of woody biomass (in billets), i.e., pine, birch, and beech. Based on the carried out research of all billets, the beech has the lowest values of CO (3497 mg/m3) and particulate matter (116.9 mg/m3). Despite this, obtained results exceed the current permissible limits based on the standard PN:EN 303-5:2012. The highest efficiency (54.13%) was obtained for birch billets, the lowest for pine (45.13%). The research has shown that the real heating efficiency during the combustion of wood, irrespective of the type of wood being burnt, is low. To summarise, the outdated installations contribute to air pollution several times higher, which indicates the need to replace inefficient heat sources using solid fuels with modern equipment that meets the most stringent standards

Comparison of Emissions and Efficiency of Two Types of Burners When Burning Wood Pellets from Different Suppliers

Wood pellets play an important role among biomass materials used as fuel. At the same time, today’s economic, environmental, political and social realities, as well as other circumstances related to fuels used for heat generation, mean that there is demand for increasingly efficient and environmentally friendly combustion sources. As is well known, each combustion source has a different efficiency due to its intended use, design, principle of operation and the type and composition of the fuel burned. The amount of pollutants emitted into the environment during combustion also largely depends on these factors. The aim of this study was to compare the flue gas emissions and efficiency of two pellet burners of different design, burning certified A1 wood pellets from different suppliers. The emission requirements were met during the combustion of wood pellets in a boiler with the two burners tested (one with a moving grate and an overfed burner). The analyses and studies carried out aim to improve the capability of managing the efficiency and environmental performance of the heat source (i.e., a boiler or a burner) and the fuel (type of wood pellets). This is done in the context of demonstrating a better combustion source when selecting the right burner and fuel in terms of efficiency and emissions. In this paper, comparisons of flue gas emissions are presented along with characteristics in the form of graphs, as well as thermal and combustion efficiencies for the corresponding solid fuel used in the form of wood pellets. After comparing the emissions, it was found that the statistical averages of CO, NOx, dust and VOCs were similar for combustion at full power using the burners tested. Taking into account the pollution levels at combustion, it can be said that the difference in CO emissions at full and minimum combustion is lower for the experimental burner compared with the moving grate burner (reference burner). In summary, it can be concluded that the experimental overfed burner under consideration can be successfully used as a solid fuel boiler to burn wood pellets

Comparison of Emissions and Efficiency of Two Types of Burners When Burning Wood Pellets from Different Suppliers

Wood pellets play an important role among biomass materials used as fuel. At the same time, today’s economic, environmental, political and social realities, as well as other circumstances related to fuels used for heat generation, mean that there is demand for increasingly efficient and environmentally friendly combustion sources. As is well known, each combustion source has a different efficiency due to its intended use, design, principle of operation and the type and composition of the fuel burned. The amount of pollutants emitted into the environment during combustion also largely depends on these factors. The aim of this study was to compare the flue gas emissions and efficiency of two pellet burners of different design, burning certified A1 wood pellets from different suppliers. The emission requirements were met during the combustion of wood pellets in a boiler with the two burners tested (one with a moving grate and an overfed burner). The analyses and studies carried out aim to improve the capability of managing the efficiency and environmental performance of the heat source (i.e., a boiler or a burner) and the fuel (type of wood pellets). This is done in the context of demonstrating a better combustion source when selecting the right burner and fuel in terms of efficiency and emissions. In this paper, comparisons of flue gas emissions are presented along with characteristics in the form of graphs, as well as thermal and combustion efficiencies for the corresponding solid fuel used in the form of wood pellets. After comparing the emissions, it was found that the statistical averages of CO, NOx, dust and VOCs were similar for combustion at full power using the burners tested. Taking into account the pollution levels at combustion, it can be said that the difference in CO emissions at full and minimum combustion is lower for the experimental burner compared with the moving grate burner (reference burner). In summary, it can be concluded that the experimental overfed burner under consideration can be successfully used as a solid fuel boiler to burn wood pellets