Residual Stress Relaxation of DRWDs in OSDs under Constant/Variable Amplitude Cyclic Loading

Abstract

An orthotropic steel deck (OSD) has a complicated structure, and its fatigue life is mainly determined by various welding details. Fatigue assessment of deck-to-rib welding details (DRWDs) under long-term train loads is an important concern for engineers. Properly assessing the initial residual stress and the mechanism of stress relaxation in DRWDs under long-term external loading is a prerequisite for predicting the fatigue damage and service life of OSDs. In this paper, a finite element analysis method is proposed to calculate the residual stress relaxation in DRWDs of OSDs under constant/variable amplitude cyclic loading. First, experiments on full-size OSD specimens were carried out using the hole drilling strain-gauge method, and the multi-axial distribution characteristics of residual stress on the sub-surface of the deck were obtained. On this basis, a refined residual stress analysis model of DRWDs using thermal-structural sequence coupling analysis and life and death unit technology is established, and the accuracy of the model is verified by the test data. Second, a coupling stress analysis model that considers the welding residual stress and mechanical stress using cyclic plastic constitutive model is established. The combined influence of number of cycles, stress amplitude, and stress ratio on multi-axial residual stress relaxation effect under constant/variable amplitude cyclic loading is investigated. Finally, a release formula of welding residual stress relaxation coefficient is proposed based on the external loading stress amplitude, stress ratio, and material yield stress. The results show that (1) with the increase in the number of loading cycles, the stress decreases until it is stabilized, while the global distribution of welding residual stress remains unchanged. Most of the welding residual stress release (about 95%) occurs in the first cycle; (2) the residual stress relaxation decreases with the increase in stress amplitude and increases linearly with the stress ratio; (3) the residual stress release is controlled by the maximum amplitude stress in the variable amplitude cyclic loading. After the residual stress is released, the stress will not continue to be released if the DRWDs have the same or smaller amplitude loading.