Professional Documents
Culture Documents
Annexure 1 0202070101 - FEA Results Rev. 02 Dated 23-02-18
Annexure 1 0202070101 - FEA Results Rev. 02 Dated 23-02-18
Code:0202070101 Rev:02
MODELLING AND CALCULATION Date: 23/02/2018 Pg.1of63
REPORT
Approval
process: Windcare
Documentation Type: Title:
Prepared:
Deliverable: DERRICK STRUCTURE STRENGTH Verified:
ANALYSIS
Approved:
SCOPE
This report focuses on Wind Care Derrick Structure strength analysis, according to the requirements imposed
by the references exposed in this document, in order to certify its safety.
KEYWORDS
RECORD OF CHANGES
ICA-TEC-001-R06 (en)Edition 1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.2of63
REFERENCES
[1] International Standard IEC 61400-1 Third edition 2005-08 Wind turbines. Part 1: Design requirements.
[2] Germanischer Lloyd. Rules and Guidelines. IV Industrial Services. Guideline for the Certification of
Wind Turbines. Edition 2010.
[3] DIBt Regulations. Edition March, 2004.
[4] Leitfaden für eine Betriebsfestigkeitsrechnung (Guideline for Fatigue Analysis), H. Gedehus, H. Zenner,
4th edition, publisher verlag staisen 1999.
[5] VDI 2230 Part 1, Systematic calculation of high duty bolted joints – Joints with one cylindrical bolt,
issued: 2003-02.
[6] ISO-898-1. Mechanical properties of fasteners made of carbon steel and alloy steel. Part 1: Bolts, studs
and screws with specified property classes. Coarse thread and fine thread.
[7] ISO-3506-1:2009 Mechanical properties of corrosion-resistant stainless steel fasternes - Part 1: Bolts,
screws and studs.
[8] EN 10025-2. Hot Rolled Products of Structural Steels – Part 2: Technical Delivery Conditions for Non-
Alloy Structural Steels.
[9] EN 1993-1-8 2005. Eurocode 3: Design of steel structures - Part 1-8: Design of joints.
[10] EN 1993-1-9 2005. Eurocode 3: Design of steel structures - Part 1-9: Fatigue.
Books
ICA-TEC-001-R06 (en)Edition 1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.3of63
Units (SI)
l Length (m)
m Mass (kg)
ρ Density (kg/m3)
F Force (N)
M Moment (Nm)
σ Stress (Pa)
a Acceleration (m/sec2)
Symbols
Abbreviations
The rest of the symbols, abbreviations and units are explained in the corresponding chapters.
ICA-TEC-001-R06 (en)Edition 1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.4of63
INDEX
SCOPE.............................................................................................................................................. 1
KEYWORDS ..................................................................................................................................... 1
RECORD OF CHANGES ..................................................................................................................... 1
REFERENCES ................................................................................................................................... 2
UNITS & SYMBOLS .......................................................................................................................... 3
INDEX .............................................................................................................................................. 4
1 INTRODUCTION ..................................................................................................................... 6
2 MARGIN OF SAFETY SUMMARY .............................................................................................. 6
2.1 ULTIMATE STRENGTH .................................................................................................................. 6
3 MATERIAL PROPERTIES ......................................................................................................... 7
3.1 METALLIC COMPONENT ............................................................................................................... 7
3.1.1 Ultimate Analysis Properties ....................................................................................................... 7
4 ALLOWABLES & PARTIAL SAFETY FACTORS .......................................................................... 9
4.1 MATERIALS ................................................................................................................................. 9
4.1.1 Ultimate Strength Analysis ......................................................................................................... 9
4.2 LOADS ........................................................................................................................................ 9
4.2.1 Ultimate Strength Analysis ......................................................................................................... 9
4.3 SUMMARY OF SAFETY FACTORS ................................................................................................... 9
5 MODEL DESCRIPTION .......................................................................................................... 10
5.1 GENERAL DESCRIPTION ............................................................................................................. 10
5.2 REFERENCE SYSTEMS ................................................................................................................ 11
5.3 COMPONENTS ........................................................................................................................... 12
5.3.1 Nacelle Framework Beam ........................................................................................................ 12
5.3.2 Lateral Connection .................................................................................................................. 13
5.3.3 Flange .................................................................................................................................... 14
5.3.4 Pulley Beam ............................................................................................................................ 15
5.3.5 Top Support ........................................................................................................................... 16
5.3.6 Stay Structure ......................................................................................................................... 16
5.3.7 Frame Beam ........................................................................................................................... 20
5.3.8 Bolted joints ........................................................................................................................... 22
5.3.9 Welded joints .......................................................................................................................... 25
5.4 INTERFACES .............................................................................................................................. 26
6 BOUNDARY CONDITIONS..................................................................................................... 28
6.1 GENERAL DESCRIPTION ............................................................................................................. 28
6.2 IMPLEMENTATION IN THE MODEL .............................................................................................. 29
7 APPLIED LOADING ............................................................................................................... 30
7.1 General description .................................................................................................................... 30
7.1.1 Pre-tension forces ................................................................................................................... 30
7.1.2 Lift Loads ............................................................................................................................... 30
7.1.3 Ultimate Load Cases Summary ................................................................................................. 30
7.2 IMPLEMENTATION IN THE MODEL .............................................................................................. 30
7.2.1 Pre-tension forces ................................................................................................................... 30
7.2.2 Lift Loads ............................................................................................................................... 31
8 CALCULATION ...................................................................................................................... 31
8.1 ULTIMATE STRENGTH ANALYSIS ................................................................................................ 31
8.1.1 Introduction............................................................................................................................ 31
8.1.2 Bolted joints ........................................................................................................................... 31
8.1.2.1 Modelled bolted joints .......................................................................................................... 31
8.1.2.2 Non modelled bolted joints ................................................................................................... 33
ICA-TEC-001-R06 (en)Edition 1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.5of63
ICA-TEC-001-R06 (en)Edition 1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.6of63
1 INTRODUCTION
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.7of63
3 MATERIAL PROPERTIES
e (%) 22 12
ν 0.3 0.3
If the calculated stress is near the elastic limit, there is a deviation between the real behaviour of the
material and the linear elastic behaviour, so the real stress is different than the FE calculated one.The
material non-linear strain will be determined using Ramberg-Osgood approximation using minored values
(γM=1.1).
1
n
0.002
E Fty
M
Where:
= total strain (elastic + plastic strain)
= stress
Fty = yield stress.
n = Ramberg-Osgood coefficient
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.8of63
In order to calculate the value of hardening coefficient n, Ramberg-Osgood curve is imposed to pass through
the ultimate strength point minored with the material partial safety factor.
The steel material curve is calculated according toTable 3-1.
The ultimate strength point is:
= 20 %
= 470/1.1= 427.3 MPa
This way, the value obtained for n is 0.061
Thus, Ramberg-Osgood equation to calculate real non-linear strain is:
1
0.061
0.002
210 E 9 323E 6
According to Neuber criteria, the transformation from the linear curve to the Ramberg-Osgood curve must
follow the equation:
const.
The value of the constant depends on the value of the stress, so each point of the linear curve has a
different value. Using non-linear techniques it is possible to solve the set of equations (shown graphically in
the figure below).
600
Ramberg-Osgood
Neuber
500
Linear-Elastic
400
300
200
100
0
0 0.002 0.004 0.006 0.008 0.01
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.9of63
The safety factors have been applied according to Germanischer Lloyd regulations (Ref. [2]) and IEC 61400-1
regulations (Ref. [1]).
4.1 MATERIALS
The partial material safety factor M used as a basis for metallic componentsand welds is M = m · n=
1.1 (with m= 1.10 and n= 1 for non-fail safe structures of component class 2) according to the specified in
IEC 61400-1, 3rd Edition Ref.[1].
For bolted connections subjected to tension and shear, the partial safety factor will be M2 = 1.25 for bolt
resistance and M3 = 1.25 for slip resistance, according to Eurocode (Ref. [9]).
4.2 LOADS
4.2.1 Ultimate Strength Analysis
Every safety factor used in the analysis is shown in the following table:
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.10of63
5 MODEL DESCRIPTION
A finite element model has been used in order to analyse the structural behaviour of the Derrick structure.
Altair HYPERMESH v14.0 (Ref. [11]) software is used as pre-processor and static analysis solver. Altair
HYPERVIEWv14.0 is used as post-processor for all performed analyses.
The model includes many beam profiles made up by steel sections. The beam profiles have been joined
between them by means of bolts modelled as single beam elements, also welded joints have been used to
the assembly. Contacts between the components have been modelled in order to prevent partial
penetrations. The bolted joints of the support structure have beenmodelled in a more detailed way. The
Figure 5-1 shows a general view of the model.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.11of63
The model coordinate systems are defined according to the rules stated on Ref. [2].Model definition is set in
the Basic or Global Coordinate System, which can be seen inFigure 5-2. The origin and the axes directions
are defined as described in Table 5-1.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.12of63
5.3 COMPONENTS
The components that constitute the Derrick Structure of Wind Care have been modelled with first order shell
elements (ABAQUS S4 and S3).Also, every subcomponent have been defined as steel S355.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.13of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.14of63
5.3.3 Flange
This components connects the lateral connection structure and the nacelle framework beam by M20
preloaded bolts. Also, Flange structure include a structure called Lateral Plates to improve performance.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.15of63
Rear zone of top support structure has been modelled with solid elements (Figure 5-13) because it works
under compression pressure and shell elements are going to show peaks values that means non-realistic
stress values.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.17of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.18of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.19of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.20of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.21of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.22of63
Middle Frame
Beam
The bolted joints of the Derrick Structure have been modeled with ABAQUS B31 beam elements. Their
section is circular and with a radius corresponding to the strength section of the bolt (A s from Ref.[5]). The
washers that contact with the steel plates have been modeled with ABAQUS C3D8 solid elements. The bolts
are joined to the solid mesh of the washers by means of CONN3D2 ABAQUS elements with BEAM properties.
These connectors are located at one extreme of the bolts, modelling the behavior of the hexagonal head in
the upper side; and at the threaded end of the screw or the nut, depending on the joint, thus connecting the
joining parts.
The total lengths of the bolts have been calculated according to the requirements in Ref.[5] when obtaining
the bolt axial resilience (chapter 5.1.1.1 of Ref.[5]), as shown inFigure 5-25.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.23of63
Figure 5-25. Division of a bolt into individual cylindrical solids and deformation regions outside the bolt from Ref.[5].
l SK 0.5 d
(8.2)
The extension length of the engaged thread part (lGM) is composed of two regions (one with the minor
diameter of the engaged bolt thread lG and the one of the tapped thread region or nut region l M). According
to VDI:
In theFigure 5-26 the beam elements of a bolt are shown. As it can be seen there, the connection between
the bolts and the solid mesh is made up by connectors rigid beam type.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.24of63
The preloaded bolted joints and their properties are listed in Table 5-2.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.25of63
Slave nodes
Master elements
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.26of63
5.4 INTERFACES
A summary of the interfaces is shown in following figures and in Table 5-3 is shown comments about
interfaces.
Tied
Contact Pair
Washers Tied -
Welds Tied -
Also, 3D model must be connected with 2D model by abaqus SHELL TO SOLID contact as ref. [14]
recommends. As in Figure 5-31 is shown, the interface between solid and shell elements has been defined
due to the structure works under compression pression.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.28of63
6 BOUNDARY CONDITIONS
The Derrick structure assembly is attached to other structure by means of 32 bolts, all of them at the stay
structure. Nodes corresponding to the bolts locations have been fixed. The position of the bolted areas is
shown in theFigure 6-1.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.29of63
The boundary condition definition has been done using kinematic couplings between the nodes located at the
hole and another node at the center of it that is restrained as is shown inFigure 6-2.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.30of63
7 APPLIED LOADING
The Derrick structure finite element model has been analyzed under the applied loading derived from Section
6.4. of Ref.[2]. The following load actions are to be taken into consideration.
7.1.1 Pre-tension forces
According to VDI Eurocode (Ref. [9]), the pretension load to be used in design calculations is shown in the
table below.
*The pretension load applied is the corresponding to the 70% yield strength.
Load
Case
Name Gravity Lift Load F Wind F Total
Figure in the following section represent the lift load case considered.
106.575 KN
8 CALCULATION
8.1.1 Introduction
In this section the strength and stability analysis methods of the components of the Derrick structure are
explained.
The Derrick structure has been analyzed against the corresponding yield limit for stress minored with the
partial material safety factor Mdescribed in 4.1.1. Regarding to the bolts, the calculation will be explained in
detail in the next points.
The finite element model has been calculated using ABAQUS v6.13-1.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.32of63
GM
GM
SK
l
l
TH TH HD
TAPPED THREAD
BOLTED JOINTS
JOINTS
Figure 8.1. Different bolt ends according to VDI 2230 Ref. [5].
Next is explained how the stress in bolts is obtained. The axial stress due to the axial force is:
Fx
axial
As (11.1)
The maximum axial stress due to the bending moment is:
M bend ·ymax
Bend
I (11.2)
In the expressions above As is the section. As the section of the bolt is circular:
·Rs 4
I
A ·Rs , y max Rs
2
4 and (11.3)
where I is the inertial moment and Rs is the minimum radius of the bolt thread.
M bend M y M z
2 2
(11.4)
This bolts stress calculation is developed in an excel spreadsheets taking into account the section forces and
moments of the bolts, extracted from the Abaqus calculations. The section forces are defined as follows, as it
is shown in Figure 8-2:
SF1: Axial section force (N)
SF2: Shear section force in direction 1(N)
SF3: Shear section force in direction 2 (N)
SM1: Bending moment along direction 1 (Nm)
SM2: Bending moment along direction 2 (Nm)
SM3: Torsional moment (Nm)
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.33of63
X
SF1 SM3
SM1
SF2
Y
Z
SF3
SM2
According to VDI 2230 (Ref. [5]), the yielding point of the bolt has not to be exceeded. The torsional stress is
only partially considered (using a reduction coefficient k = 0.5).
For the tension stress, the maximum loaded fiber of the bolt is used. It tension is calculated with the FEA
obtained axial force Fax and bolt section bending moment Mbend:
Z axial Bend (8.6)
In the case of the torsional stress due to tightening method, it is calculated with:
MG
(8.7)
WP
In that expression the used FMzul is the bolt pretension, d2 is the pitch diameter of the bolt thread, P is the
thread pitch and G min is the friction coefficient in the thread (here 0.10 has been used). From the
expression (11.7) the inertial polar moment is calculated as:
WP d 03 (8.9)
16
where d0 is the diameter of the relevant smallest cross section of the bolt (here d 0 = ds is used).
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.34of63
Ft , Ed Ft , Rd
Fv , Ed Fv , Rd
Fv , Ed Fb , Rd , Steel
Fv , Ed Fb , Rd ,Composite
Fv , Ed Ft , Ed
1
Fv , Rd 1.4·Ft , Rd
Where:
Ft,Ed is the design tensile force per bolt for the ultimate limit state;
Fv,Ed is the design shear force per bolt for the ultimate limit state;
Ft,Rd is the design tension strength per bolt;
Fv,Rd is the design shear strength per bolt;
FB,Rd,Steel is the design strength of the steel profile per bolt.
FB,Rd,Composite is the design strength of the composite laminate per bolt.
The acting loads are obtained from the Derrick Structure FE Model and from each load case. The allowable
loads for each bolt depend on its material properties, metric and configuration. Next, the expressions used
for calculating the allowable values are presented:
Tension resistance, Ft,Rd:
k 2 · f u ,b ·As
Ft ,Rd
M2
The shear strength of the bolt, Fv,Rd :
v· fu ,b·A
Fv , Rd
M2
The bearing strength of the steel profile, Fb,Rd Steel:
t ·D· f u ,S 355
Fb,Rd ,Steel 1.5· s
M2
Where:
K2 takes a value of 0.9 according to Table 3.4 of Ref.[9].
As is the stress cross section area of the bolt (seeTable 5-2)
fub is the ultimate tensile strength of the bolt.
M2 is the partial safety factor; see section 4.1.1 of the current document.
v , takes a value of 1.0 for bolts in normal holes and 0.63 for long slotted holes according to Table
3.4 of Ref. [9].
ts are the thickness of the steel flange.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.35of63
D is the diameter of the hole on the steel profile or solid laminate (conservatively the bolt diameter is
assumed).
fu,S355 is the ultimate tensile strength of the steel that has been used in the model.
In order to carry out the strength analysis, the tension and shear forces are extracted directly from the
boundary nodes in the FE model.
Abaqus section force SF1 represents the axial force in a beam element while SF2 and SF3 the shear forces in
two orthogonal directions in the cross section plane. Hence, Ft,Ed and Fv,Ed are calculated in this way:
Ft ,Ed SF1
Fv ,Ed SF 23 SF 2 2 SF 32
Where,
SF1 is the section force in the beam direction (axial);
SF2 is the section force in local 1 direction (section plane);
SF3 is the section force in local 2 direction (section plane);
SF23 is the resultant shear force (section plane).
The margin of safety for each ultimate limit state is calculates as show below:
Ft ,Ed
MSt 1
Ft ,Rd
Fs ,Ed
MS s 1
Fv ,Rd
Fb ,Ed
MSb 1
Fb ,Rd
F Ft ,Ed
MS c 1 v ,Ed
Fv ,Rd 1.4·Ft ,Rd
Where,
MSt is the margin of safety for tension resistance,
MSs is the margin of safety for slip resistance,
MSb is the margin of safety for bearing resistance,
MSc is the margin of safety for combined tension and shear.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.36of63
From the ABAQUS analysis, total forces and total moments about to the origin due to the contact pressure
and frictional stress of all welded joints tied contacts are obtained. Stresses at each fillet of the welds are
studied to validate the welded joints. The procedure to get the stresses from the section forces of one
welded joint is summarized below:
From the Abaqus analysis, total forces and total moments about to the origin due to the contact pressure and
frictional stress for each welded joint are obtained.
First, forces and moments at each node must be translated to the origin of the welded joint with the
expressions:
RG RO
M G M O GO RO
Where R are the forces, M the moments, the subscript G refers to the origin of the weld and the subscript O
refers to the node origin.
The summation of these forces and moments considering only the contribution of the elements from one of
the parts connected is what is called section forces or free body cut, and represents what the welded joint
must stand. Then, the aim of the weld analysis is to check if the welded joint can either stand these forces or
not.
After that, it is important to change the coordinate system: from the global one to the welded joint local
coordinate system. The reason of the coordinate system change is that this way, all weld joints have the
same orientation at their local coordinate system and then, the force distribution calculation is less
complicated. In Figure 8-3, axes x and y correspond to the weld local coordinate system and the point G is
the origin of the weld.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.37of63
Y Y
A B
X G X
G
Weld sections described in section 5.3.9 are composed of many fillets, as the example given in Figure 8-4.
Then, it is necessary to find the forces and moments at each fillet in order to analyze their stress level.
According to Ref. [9], it must be defined a distribution of forces and moments which complies with the
following conditions:
For the Spinner weld fillets, distribution hypotheses fulfilling these considerations have been made.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.38of63
From the forces at each weld, it is possible to calculate its stress level. According to Ref. [9], only one normal
stress and two shear stresses are considered in the verification of the design resistance of the model, as it is
shown in Figure 8-5.
These stresses shown in Figure 8-5 are expressed at the weld throat coordinate system, which is not the
same as neither the weld joint local coordinate system nor the global system defined.
According to Ref. [9], the design resistance of one fillet will be sufficient if the following expressions are both
satisfied:
fu
W M 2
MoSWELD1: Equivalent stress: 1 0
3( 2 ll2 )
2
0.9 f u
M2
MoSWELD2: Normal stress: 1 0
Where fu is the ultimate tensile strength of the weakest part joined, w is a correlation factor (0.9 for S355
steel according to Table 4.1 of Ref. [9]) and M2 is the material safety factor (described in section 4.1.2).
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.39of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.40of63
9 RESULTS
In the next figures, the ultimate strength analysis results with linear material definition are shown.
Firstly, for steel structures, Von Mises stress maps will be presented. Finally, summary tables with bolts and
welds results will be shown.
9.1.1 Ultimate Strength Linear Material Analysis
Figure 9-1Displacements: Derrick Structure, Pulley Weight case (scale x10). General view 1.
511.40 MPa
Figure 9-2Von Mises stress: Derrick Structure, Pulley Weight case. General view 1.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.41of63
Figure 9-3Von Mises stress: Front Beam Structure, Pulley Weight case. Detailed view.
Figure 9-4Von Mises stress: Middle Beam1 Structure, Pulley Weight case. Detailed view.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.42of63
Figure 9-5Von Mises stress: Middle Beam2 Structure, Pulley Weight case. Detailed view.
Figure 9-6Von Mises stress: End Beam Structure, Pulley Weight case. Detailed view.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.43of63
Figure 9-7Von Mises stress: Top Support Structure, Pulley Weight case. Detailed view.
Figure 9-8Von Mises stress: Front Pulley Beam Structure, Pulley Weight case. Detailed view.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.44of63
Figure 9-9Von Mises stress: Back Pulley Beam Structure, Pulley Weight case. Detailed view.
Figure 9-10Von Mises stress: Front Frame Beam Structure, Pulley Weight case. Detailed view.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.45of63
Figure 9-11Von Mises stress: Middle Frame Beam Structure, Pulley Weight case. Detailed view.
Figure 9-12Von Mises stress: End Frame Beam Structure, Pulley Weight case. Detailed view.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.46of63
Figure 9-13Von Mises stress: Stay Post Structure, Pulley Weight case. Detailed view.
Figure 9-14Von Mises stress: Nacelle Beam Structure, Pulley Weight case. Detailed view.
In Figure 9-2, Figure 9-13 and Figure 9-14 there are points where the stress is higher than the yield limit.
The higher stress zone has been analysed through an elastic-plastic material analysis using the minored
Ramberg-Osgood curve for the material.
To clarify the image with stress 511.40 MPa (Figure 9-2) it has been made a submodel to show the
compression effect.The submodel has been attached between the 2D model and 3D model with a shell to
solid contact.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.47of63
Figure 9-15Von Mises stress: Derrick Structure, Pulley Weight case. Submodel 1.
In the same way, to clarify Figure 9-7 non-real stress peaks values it has been made another submodel to
show the compression effect.
Figure 9-16Von Mises stress: Derrick Structure, Pulley Weight case. Submodel 2.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.48of63
244.30 MPa
Figure 9-17Von Mises stress: Derrick Structure, Pulley Weight case. General view 2.
Figure 9-18Von Mises stress: Derrick Structure, Pulley Weight case. General view 3.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.49of63
Figure 9-19: Von Mises stress: Pin, Pulley Weight case. Detailed view.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.50of63
As can be observed in the previous table, the maximum stress appears in the Nacelle Framework with a
value of 511.90 MPa, which is over the maximum material allowable stress. However, it has been
demonstrated that deformation values are under 0.38%, which is much lower than the failure strain value
(1%). In addition to this, the value has been obtained through an elastic-plastic calculation using the
minored Ramberg-Osgood curve for the material, being this a conservative procedure, as seen in
section3.1.1. In conclusion, the Derrick Structure complies with the ultimate strength safety requirements.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.51of63
In the following tables, envelope results of the margins of safety for every bolted joint is presented.
σ total
Preloaded bolted joint MS
(MPa)
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.52of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.53of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.54of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.55of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.56of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.57of63
10 CONCLUSIONS
The stresses for the Derrick structure are lower than the allowable limit of 323MPa. In addition, all checks
made to the bolted and welded joints have positive margins of safety.
Therefore, it can be concluded that the Derrick structurecomplies with the requirements for ultimate
strength analysis according to the established requirements.
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.58of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.59of63
GDM-TEC-001-R01 ed1
Confidentiality: 0 / CONFIDENTIAL INFORMATION
Code: 0202070101 Rev:01
MODELLING AND CALCULATION REPORT
Date: 23/02/2018 Pg.60of63
GDM-TEC-001-R01 ed1