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Proposed residual stress model for roller bent steel wide flange sections
R.C. Spoorenberg a,b, , H.H. Snijder b , J.C.D. Hoenderkamp b
a
Materials Innovation Institute M2i, P.O. Box 5008, 2600 GA Delft, The Netherlands
Eindhoven University of Technology, Faculty of Architecture, Building and Planning, Den Dolech 2, P.O. Box 513, 5600 MB Eindhoven, The Netherlands
article
info
Article history:
Received 28 July 2010
Accepted 13 January 2011
Keywords:
Residual stress model
Curved steel
Roller bending
Wide flange section
abstract
The manufacturing process of structural wide flange steel sections introduces residual stresses in the
material. These stresses due to hot-rolling or welding influence the inelastic buckling response of
structural steel members and need to be taken into account in the design. Based on experimental data
standardized residual stress models have been proposed for inclusion in inelastic buckling analyses.
By incorporating these residual stress models their effect on the resistance of beams and columns can
be obtained. Residual stress models for roller bent steel sections are currently not available. Roller
bent wide flange sections are manufactured by curving straight members at ambient temperature. This
manufacturing technique, which is also known as roller bending, stresses the material beyond its yield
stress, thereby overriding the initial residual stresses prior to bending and generating an entirely new
pattern. This paper proposes a residual stress model for roller bent wide flange sections, based on
earlier conducted numerical investigations which were validated by experimental research performed
at Eindhoven University of Technology. The proposed residual stress model can serve as an initial state of
a roller bent steel section in fully non-linear finite element analyses to accurately predict its influence on
the inelastic buckling response.
2011 Elsevier Ltd. All rights reserved.
1. Introduction
(a) Hot-rolled.
(b) Welded.
993
Fig. 1. Indicative residual stress patterns for hot-rolled, welded and roller straightened sections.
994
Fig. 3. Adopted residual stress patterns for studying inelastic buckling behavior of steel arches.
thickness and the flange thickness. The finite element model was
not developed to simulate the residual stress gradients over the
web thickness and the flange thickness. However, it yields averaged residual stresses over the web and flange thickness for the entire cross section. An experimental approach for obtaining residual
stresses cannot yield data for the entire cross section due to placement requirements of the strain gauges. It was therefore decided
to employ finite element analyses to generate residual stresses
which can be used in the development of a proposal for a roller
bent residual stress model, thereby ignoring residual stress gradients over the web thickness and the flange thickness. In view of
earlier developed residual stress models [4,10] for straight steel
members, which also ignored the measured residual stress gradient over the web thickness and the flange thickness, this simplification was considered appropriate. Residual stresses were obtained
for a total of 18 wide flange steel sections by simulation in the
finite element environment. Two steel grades, four different sections and five bending radii were used which yielded 8 different
bending ratios (Table 1). The bending ratio equals the radius of the
circular arch divided by the nominal height of the cross section. An
increase of the bending ratio means a decrease of the degree of cold
working, when the height of the section is kept constant. As part of
the experimental procedure to measure residual stresses, tensile
tests were performed on coupons taken from the flanges of straight
reference sections to obtain the yield stress and ultimate tensile
stress, according to NEN-EN 10002-1 [26] and EN 10025 [27]. These
straight sections were originally attached to the roller bent specimens and give information on the state of the material prior to
roller bending. Dividing the numerically obtained residual stresses
by the measured yield stresses of the straight material gives normalized residual stress values.
It has been shown by Spoorenberg et al. [16] that close agreement can be attained between finite element analyses and experimental results for the averaged residual stresses over the web
995
Table 1
Mechanical properties and bending ratio of steel members.
Section type
Steel grade
S235
HE 100A
S355
S235
HE 100B
S355
HE 360B
S235
S355
S235
IPE 360
S355
Yield stress fy
Tensile stress ft
1910
2546
3820
1910
2546
3820
322
279
433
418
364
566
1910
2546
3820
1910
2546
3820
248
285
411
412
386
390
492
495
8000
8000
269
357
389
534
22.22
22.22
4500
8000
4500
8000
297
414
361
528
12.5
22.22
12.5
22.22
19.89
26.52
39.79
19.89
26.52
39.79
19.1
25.46
38.2
19.1
25.46
38.2
analyses are consistently located in the bottom flange at the webto-flange junction and flange tips respectively. It was therefore decided that the residual stress patterns across the bottom flange,
which was subjected to compressive actions during roller bending, would be used to investigate the influence of bending ratio and
original yield stress.
2.2. Influence of bending radius
The amount of cold work or plastic straining applied during
roller bending may affect the magnitude of the residual stresses.
For steel exhibiting a clear hardening stage, a decrease of the
bending ratio is expected to induce higher residual stresses. For
each steel section as presented in Table 1, the numerically obtained
maximum tensile and maximum compressive normalized residual
stresses in the bottom flange are displayed as a function of the
bending ratio in Fig. 5(left). It can bee seen that the bending ratio
has no clear influence on the extreme residual stresses within
the examined range of 12.5 R/h 39.79. Consequently a
residual stress model can be developed which is independent of
the bending radius, and applicable to a bending ratio range of
approximately 10 R/h 40.
Fig. 4. Normalized residual stresses in 18 roller bent wide flange sections.
996
Fig. 5. Normalized maximum tensile and compressive residual stresses in the bottom flange versus bending ratio (left) and maximum tensile and compressive residual
stresses in the bottom flange versus yield stress of original material (right).
(a) Dimensions.
Fig. 6. Proposed residual stress model for roller bent wide flange steel sections.
+
wrt
8
4
1
1
+
+
wrc
fy = 0
8
4
7
1 1
1
5
M =
btf h0 + tw
h0 + h0
wrt
80
8 6
4 12
1
7
1 5
+
h0
+ h0
wrt
fy = 0.
N =
80
btf + tw h0
12
(1)
wrt + wrc
fy = 0
8
1
7
1
h0 fy = 0,
M =
btf h0 + h0 tw
wrt + wrc
N =
80
btf + tw h0
80
(2)
N
M
3
8
= fy h0 tw
1
h0
3
8 wrt
1 wrc
h0
fy
btf
80
80
0
.
0
(3)
wrt =
7btf
30h0 tw
fy ,
wrc =
14btf
30h0 tw
fy .
btf h0
997
(4)
With these values the residual stress model for roller bent wide
flange steel sections is complete.
3.2. Residual stress model features
From Eq. (4) it is clear that the requirement of internal
equilibrium renders the proposed model to be different per section
geometry. The residual stress values in the web are governed by
the ratio between the area of the flange and area of the web.
The proposed model is qualitatively identical for all wide flange
sections but the magnitude of the residual stresses in the web is
dependent on the geometry of the cross section.
Fig. 4 shows that the numerical residual stress pattern is
featured by a sharp stress gradient at the web-to-flange junctions
of the roller bent wide flange sections. This sharp stress gradient
has been approximated in the proposed residual stress model by a
so-called stress jump at the web-to-flange junctions (i.e. the stress
value at the top of the web or bottom of the web is different from
the stress value in the middle of the top flange or middle of the
bottom flange, respectively). A stress jump is a stress change over
an infinitesimal distance and can also be found in residual stress
models for welded sections, [20] (Fig. 3(b)). Modeling the large
stress gradients instead of the stress-jumps in the web-to-flange
junctions in a residual stress model would significantly complicate
the stress pattern in the web and improve its accuracy only
marginally as the pertaining section areas are extremely small.
The stress jump provides therefore a simplification to the residual
stress model and enhances the simplicity of the equilibrium
equations and ease of applicability when employed in numerical
models.
4. Discussion
4.1. Comparison to experiments
Residual stress measurements were performed on both straight
and roller bent sections using the sectioning method. Measurements taken from both sides of the flanges and the web were used
to obtain the average residual stress values. Residual stresses in
HE 100A, HE 360B and IPE 360 sections were published earlier
by Spoorenberg et al. [15]. A full overview of the averaged experimental results compared with the suggested residual stress
model is shown in Fig. 7. The averaged experimental results for
roller bent sections and the suggested residual stress model are
plotted against the location over the section normalized by the
998
Fig. 7. Normalized measured averaged residual stresses and proposed residual stress model.
a residual stress model. It was found that the bending ratio does
not influence the magnitudes of the residual stresses, allowing for
a residual stress model representing all examined bending radii
for 10 R/h 40. The residual stresses were found to be
linearly dependent on the yield stress of the original material and a
single normalized residual stress model could therefore represent
all roller bent sections, for steel grades S235 and S355.
Based on a best fit of the finite element data, the proposed
linear stress gradient along the width of the top flange (the
flange that is plastically elongated in longitudinal direction during
roller bending) is featured by stress magnitudes of 0.2fy in
tension and 0.2fy in compression at the flange tips and flange
center respectively. The residual stress in the bottom flange (the
flange that is plastically shortened in longitudinal direction during
999
Fig. 8. Normalized computed residual stresses and proposed residual stress model.
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