Production Specification

Info No.: Ident No.:

393 415 Improvement of Fatigue Strength 0 74 31 36 - 3.
Scale: Size: by Grinding of Weld Toes Page No.:
A4 (6)
Similar Drawing No.: Replacement for Ident. No.:
Date: Des. Chk. Appd. Photo date A. C. Change / Replacement C. No.:
20040318 THR 20040510 0
20040716 THR Z4 Specification changed from QS to PS new fig. 3 and general revision 1
20050512 THR Z4 Sub-section 6.5 new plus minor correction in section 4 and 7. 2
20050929 THR Z4 Sect. 4. Grinding with disc grinder and sect. 7. MT testing is added. 3
20060630 THR Z4 Item 2 is updated, Item 7 is clarifyed & Ra 6,3 => Ra 12,5 4
5
6
7
8
Replaced by Ident. No.: 9

This document is valid for the following engine types:

L42MC, L42MC-S, S42MC, S46MC-C, K50MC-S, L50MC, S50MC, S50MC-C, K60MC-S,

L60MC, L60MC-C, S60MC, S60MC-C, L70MC, L70MC-C, S70MC, S70MC-C, K80MC-S,
K80MC-C, L80MC, S80MC, S80MC-C, K90MC-S, K90MC, K90MC-C, L90MC, L90MC-C,
S90MC-C, K98MC-S, K98MC, K98MC-C.
S50ME-C, L60ME-C, S60ME-C, S65ME-C, L70ME-C, S70ME-C, K80ME-C, L80ME,
S80ME-C, K90ME-C, K90ME, L90ME-C, S90ME-C, K98ME-C, K98ME, K108ME-C.

Contents

1. Scope
2. Introduction
3. References
4. Training of grinding personnel
5. Tools
6. Grinding correctly
7. Verification of grinding result.

1. Scope

The purpose of this production specification is to make sure that the grinding of the weld toe is
done correctly according to requirements.
This specification can also be used for improvement of fatigue strength on repair welds.
 Production Specification
Info No.: Ident No.:
393 415 Improvement of Fatigue Strength 0 74 31 36 - 3.
Scale: Size: by Grinding of Weld Toes Page No.:
A4 (6)
Similar Drawing No.: Replacement for Ident. No.:
Date: Des. Chk. Appd. Photo date A. C. Change / Replacement C. No.:
20060630 THR Z4 Item 2 is updated, Item 7 is clarifyed & Ra 6,3 => Ra 12,5 4

2. Introduction

Fatigue strength of welded connections can be improved by grinding of the weld toes.
In a welded construction with grinding of welding toes (this is seen on the drawings, see
fig 3), the plate thicknesses are reduced up to 30 %, compared with similar design without
grinding of welding toe. If the grinding is not performed correctly e.g. if the undercut is not
removed completely, the fatigue strength is reduced compared to the design calculations, and
the construction might fail during service.
Grinding gives two advantages in respect to fatigue strength:

- Firstly grinding removes the weld toe flaws e.g. undercut from which fatigue cracks can
initiate.
- Secondly grinding reduces the local stress concentration by smoothly blending the
transition between the plate and the weld face.
To be able to benefit from this improvement, the grinding has to be preformed correctly.

3. References

MAN B&W Quality control No 0742078-2; Visual Inspection of Welded Components.

MAN B&W Production Specification No 0742818-8; Requirements for Welding
Workmanship.
MAN B&W Standards EN 601 M: Quality classes for imperfections of welded joints.
IIW recommendations on Post Weld Improvement of Steel and Aluminium Structures, P. J.
Haagensen and S. J. Maddox XIII-1815-00 Revised 4 July 2001.

4. Tools

High speed pneumatic, hydraulic or electrical grinder with rotational speed from 15 000 to 40
000 rpm is recommended, called “burr grinder”.
For air driven grinders the air pressure of 5 – 7 bar is recommended (see Fig. 1).

Figure 1

There is a possibility to speed up the process are by using a disc grinder, followed by using burr
 Production Specification
Info No.: Ident No.:
393 415 Improvement of Fatigue Strength 0 74 31 36 - 3.
Scale: Size: by Grinding of Weld Toes Page No.:
A4 (6)
Similar Drawing No.: Replacement for Ident. No.:
Date: Des. Chk. Appd. Photo date A. C. Change / Replacement C. No.:
20060630 THR Z4 Item 2 is updated, Item 7 is clarifyed & Ra 6,3 => Ra 12,5 4

grinder (see fig. 2).

Figure 2

5. Training of personnel for grinding

Before any person starts grinding of weld toe the operator must be submitted to training where
the operator is instructed in section 6. “Grinding correctly” and the operator must also show,
by grinding minimum 2 meters of weld toe similar to the actual production; so the operator can
show that the operator is able to perform the grinding correctly.
 Production Specification
Info No.: Ident No.:
393 415 Improvement of Fatigue Strength 0 74 31 36 - 3.
Scale: Size: by Grinding of Weld Toes Page No.:
A4 (6)
Similar Drawing No.: Replacement for Ident. No.:
Date: Des. Chk. Appd. Photo date A. C. Change / Replacement C. No.:
20060630 THR Z4 Item 2 is updated, Item 7 is clarifyed & Ra 6,3 => Ra 12,5 4

6. Grinding correctly

6.1 Radius of grinding

When grinding is stated on MAN B&W drawings; the radius is stated on the drawing as shown
on Fig. 3.

Figure 3

In case of improvement of fatigue strength in case of rectification, the radius is of the grinding is
not stated on MAN B&W drawings, we can calculate the radius. The radius must be larger than
0.25 x t where “ t ” is the thickness of the plate, see fig 4.

Figure 4

r  0.25  t

t
 Production Specification
Info No.: Ident No.:
393 415 Improvement of Fatigue Strength 0 74 31 36 - 3.
Scale: Size: by Grinding of Weld Toes Page No.:
A4 (6)
Similar Drawing No.: Replacement for Ident. No.:
Date: Des. Chk. Appd. Photo date A. C. Change / Replacement C. No.:
20060630 THR Z4 Item 2 is updated, Item 7 is clarifyed & Ra 6,3 => Ra 12,5 4

6.2 Grinding angles

The angle of the burr according to horizontal (the main plate) is 45-60°.
The angle of the burr according to travel direction is 30-45°, the grinding is done with leading
tool angle (pushing). (Fig. 5)

Figure 5

6.3 Depth of grinding

Minimum grinding is 0,5 mm below any visual undercut; we suppose that the “normal” undercut
is 0,1 mm, which will result in minimum grinding of depth 0,6 mm.
Maximum grinding is 7% of plate thickness.
If the grinding should exceed 7% of the plate thickness, repair welding must be performed. After
repair welding new grinding must be performed.
6.4 Advise on welding before grinding
Weld with a welding technique that results in very small undercuts, this may reduce grinding
dramatically.
6.5 Roughness
The roughness of the grinding must be max. Ra 12.5.
 Production Specification
Info No.: Ident No.:
393 415 Improvement of Fatigue Strength 0 74 31 36 - 3.
Scale: Size: by Grinding of Weld Toes Page No.:
A4 (6)
Similar Drawing No.: Replacement for Ident. No.:
Date: Des. Chk. Appd. Photo date A. C. Change / Replacement C. No.:
20060630 THR Z4 Item 2 is updated, Item 7 is clarifyed & Ra 6,3 => Ra 12,5 4
7. Verification of grinding result.

It is essential that the grinding is done properly; this is why verification of grinding result is
very important.
During verification of grinding result the following must be checked:

- There must be no non-ground areas, in the ground zones.

- The ground zone must be inspected by visual inspection with a torch.
- There must be absolutely no defects like undercut in the ground zone.
- The roughness in the grinding zone must be max. Ra 12.5
- Magnetic testing (MT) is to be applyed after grinding. There must be absolutely no
defects like undercut in the ground zone.
The grinding must be at least 0,6 mm deep according to item 6.3. This can be inspected by
means of different tools e.g. a weld gauge,- see Fig 6.

Figure 6