Search for Author, Title, Keyword
Fatigue lifetime correction of structural joints Indexed by: of opencast mining machinery
More details
Hide details
Warsaw University of Technology, Institute of Vehicles and Construction Machinery Engineering, ul. Narbutta 84, 02-524 Warsaw, Poland
Publication date: 2021-09-30
Eksploatacja i Niezawodność – Maintenance and Reliability 2021;23(3):530–539
  • The novel comprehensive approach to fatigue design of welded superstructures was presented.
  • Functionality of the method has been developed and verified on the real object remaining in operation.
  • Fatigue lifetime correction results for long-time operated object was provided.
  • The procedure improves fatigue lifetime assessments credibility and helps to provide requested lifetime.
  • The method aids maintenance of superstructure providing information about its technical condition.
Opencast mining machinery represents a group of large-scale individually manufactured technical objects operated with long-life requests. Since their manufacturers are obliged to provide product that will reach declared time of life, fatigue strength and durability conditions have to be taken into account for superstructures to meet the requirements. The paper highlights main problems occurring while assessing fatigue lifetime during design. Firstly, the short survey of current state of the art regarding the approach to this problem is presented. Secondly, the most important reasons of unsatisfactory accuracy of the assessments are discussed. As a main objective of the study, the authors introduce the unique method of continuous fatigue lifetime correction for the welded superstructures during the machine lifecycle, as a remedy for this group of machinery. Furthermore, results and experience from adapting the approach in real object are presented, including fatigue lifetime correction due to the real intensity of loading acquired from a bucket-wheel excavator during its longlasting operation. It is expected that proposed procedure can help to improve credibility of fatigue lifetime assessment of heavy earthmoving machinery.
Akpan UO. et al. Risk assessment of ageing ship hull structures in the presence of corrosion and fatigue. Marine Structures 2002; 15 (3): 211-231,
Alenowicz J, Rosik R. Requirements for load carrying structures of BWE operating in hard mineable soils. Górnictwo Odkrywkowe 2016; 57 (6): 77-82.
AS 4324.1, Mobile equipment for continuous handling of bulk materials - Part 1: General requirements for the design of steel structures, Standards Australia, 2017.
Åstrand E. Key changes in the welding of fatigue loaded structures. Chalmers Conferences. The 6th Swedish Production Symposium. Gothenburg, 2014.
Babiarz S, Dudek D. Failure and disaster chronicle of the machine in Polish surface mining. Wrocław University of Technology Publishing House, Wrocław, 2007 [ in Polish].
Biały W. Selected methods of measuring coal's mineability. Eksploatacja i Niezawodnosc - Maintenance and Reliability 2001; 5: 36-40.
Bošnjak SM. et al. External load variability of multibucket machines for mechanization. Advanced Materials Research 2012; 422: 678-683,
Bošnjak SM. et al. Cracks, repair and reconstruction of bucket wheel excavator slewing platform. Engineering Failure Analysis 2009; 16: 1631-1642,
Bošnjak SM., Zrnić NĐ. Dynamics, failures, redesigning and environmentally friendly technologies in surface mining systems. Archives of Civil and Mechanical Engineering 2012; 12: 348-359,
Deng L, Yan W, Nie L. A simple corrosion fatigue design method for bridges considering the coupled corrosion-overloading effect. Engineering Structures 2019; 178: 309-317,
DIN 22261-2, Excavators, spreaders and auxiliary equipment in brown coal opencast lignite mines - Part 2: Calculation Principles, German Institute for Standardization, 2015.
Dittrich W, Dralle HJ. Inspection of opencast mine equipment. World of Mining 2007; 59 (1): 22-26.
Directive 2006/42/CE of The European Parliament, of The Council of 17th May 2006 on machinery, and amending Directive 95/16/CE (recast).
EN 13001-3-1, Cranes - General design - Part 3-1: Limit states and proof of competence of steel structures, 2018.
Fathalla E, Tanaka Y, Maekawa K. Remaining fatigue life assessment of in-service bridge decks based upon artificial neural networks. Engineering Structures 2018; 171: 602-616,
Froseth GT, Ronnquist A. Load model of historic traffic for fatigue life estimation of Norwegian railway bridges. Engineering Structures 2019; 200,
Gołaś A, Iwaniec M, Szopa K. Hashed data transfer in SHM distributed systems with the use of Power Line Communication technology. Key Engineering Materials 2012; 518: 54-159,
Hobbacher A. Recommendations for Fatigue Design of Welded Joints and Components. International Institute of Welding, document IIW-1823-07 (ex XIII-2151r4-07/XV-1254r4-07), Paris, 2008.
Huang B, Wang S, Geng S, Liu X. Improved numerical model for fatigue cumulative damage of mechanical structure considering load sequence and interaction. Advances in Mechanical Engineering 2021; 13 (2): 1-9,
ISO 20332-1, Cranes - Proof of competence of steel structures - Part I: General, 2016.
Jakubczak H, Jankowiak A, Sobczykiewicz W, Kowalczyk M. Technical basis of management with risk caused by fatigue cracking of loadbearing constructions of working machines. Górnictwo Odkrywkowe 2011; 52 (3-4): 61-70.
Jankowiak A, Grabowski P, Kowalczyk M. Bearing structures fatigue. Resource assessment during long-lasting exploitation of machines. Part 1 - loading data acquisition problems in long-lasting exploitation. Górnictwo Odkrywkowe 2018; 5: 15-25.
Jankowiak A, Grabowski P, Kowalczyk M. Bearing structures fatigue. Resource assessment during long-lasting exploitation of machines. Part 2 - substitutive methods of fatigue life assessment in long periods of time. Górnictwo Odkrywkowe 2018; vol. LVIV, 5: 26-32.
Jovančić P.D, Ignjatović D, Tanasijević M, Maneski T. Load-bearing steel structure diagnostics on bucket wheel excavator for the purpose of failure prevention. Engineering Failure Analysis 2011; 18: 1203-1211,
Kowalczyk M, Sobczykiewicz W. Problems of PEX exploitation project realization in the range of fatigue life of opencast mining machines load-bearing structures. Górnictwo Odkrywkowe 2011; 52 (3-4): 71-79.
Kowalewski J. Assessment of Remaining Fatigue Life for Surface Mining Equipment. Surface Mining. Braunkohle & Other Minerals 2001; 53 (4): 405-416.
Kuhn B. Assessment of existing steel structures - Recommendations for estimation of the remaining fatigue life. 5th Fatigue Design Conference, Fatigue Design 2013, Procedia Engineering 2013; 66: 3-11,
Kuhn B. et al. Assessment of existing steel structures: Recommendations for estimation of remaining fatigue life. Background documents on support the implementation, harmonization and further development of the Eurocodes - joint report. Joint Research Center Scientific and Technical Reports, 1st Edition, 2008,
Love PED, et al. What goes up, shouldn't come down: learning from construction and engineering failures. Procedia Engineering 2011; 14: 844-850,
Maddox SJ. Review of fatigue assessment procedures for welded aluminium structures. International Journal of Fatigue 2003; 25 (2): 1359-1378,
May QA. et al. Prediction of remaining fatigue life of welded joints in wind turbine support structures considering strain measurements and a joint distribution of oceanographic data. Marine Structures 2019; 66: 307-322,
Miner M. Cumulative fatigue damage. Journal of Applied Mechanics 1945; 12: A159-A164,
Moczko P, Pietrusiak D, Rusiński E. Material handling and mining equipment - international standards recommendations for design and testing. FME Transactions 2018; 46: 291-298, http://dx/
Onichimiuk M, Wygoda M, Figiel A. Long-term load tests of opencast mining excavators. Górnictwo Odkrywkowe 2013; 54 (3-4): 24-29.
Palin-Luc T et al. Fatigue crack initiation and growth on a steel in the very high cycle regime with water corrosion. Engineering Fracture Mechanics 2010; 77 (11): 1953-1962,
Petinov S. In-service fatigue service reliability of structures. Solid Mechanics and Its Applications, vol. 251. Springer, 2018. ISBN 978-3-319-89317-4.
Pietrusiak D. Evaluation of large-scale load-carying structures of machines with the application of the dynamic effects factor. Eksploatacja i Niezawodnosc - Maintenance and Reliability 2017; 19 (4): 542-551,
PN-G-47000-2, Opencast mining - Bucket Wheel Excavators and Spreaders - Part 2: Calculation Fundamentals, 2011.
Rusiński E. et al. Surface mining machines: problems of maintenance and modernization. Springer, 2017, ISBN 978-3-319-47792-3.
Rusiński E. et al. Guidelines for the design of opencast mining machines. Górnictwo Odkrywkowe 2018; 4: 114-119.
Rusiński E. et al. An analysis of the causes of a BWE counterweight boom support fracture. Engineering Failure Analysis 2010; 17:179-191,
Rusiński E, Czmochowski J, Pietrusiak D. Selected problems in designing and constructing surface mining machinery. FME Transactions 2012; 40: 153-164.
Rusiński E, Moczko P, Pietrusiak D. Low frequency vibrations of the surface mining machines caused by operational loads and its impact on durability. Proceedings of ISMA 2014, Leuven, 2014, ISBN 978-9-073-80291-9.
Schmidt MJ. Structural failures on mobile materials handling equipment. Dissertation. University of Pretoria, 2014.
Schmidt MJ, van Rensburg BWJ Avoiding structural failures on mobile bulk materials handling equipment. The Journal of The Southern African Institute of Mining and Metallurgy 2015; 115: 179-184,
Shen F, Zhao B, Li L, Chua C.K, Zhou K. Fatigue damage evolution and lifetime prediction of welded joints with the consideration of residual stresses and porosity. International Journal of Fatigue 2017; 103: 272-279,
Sikora M, Szczyrba K, Wróbel Ł, Michalak M. Monitoring and maintenance of a gantry based on a wireless system for measurement and analysis of the vibration level. Eksploatacja i Niezawodnosc - Maintenance and Reliability, 2019; 21 (2): 341-350,
Siriwardane S, Ohga M, Dissanayake R, Taniwaki K. Application of New damage indicator-based sequential law for remaining fatigue life estimation of railway bridges. Journal of Constructional Steel Research 2008; 64: 228-237,
Sobczykiewicz W. Fatigue life of welded load carrying structures with respect to quality. Technology, Law and Insurance 1999, 4: 251-256,
Sobczykiewicz W, Kowalczyk M. Accomplishing the required fatigue life of load-carrying machine structures. Traditional approach. Górnictwo Odkrywkowe 2009; 50 (4-5): 115-122.
Szopa K, Iwaniec M, Iwaniec J. Identification of technical condition of the overhead power line supporting structure. Eksploatacja i Niezawodnosc - Maintenance and Reliability 2019; 21 (1): 115-124,
Woch M. Reliability analysis of the PZL-130 Orlik TC-II aircraft structural component under real operating conditions. Eksploatacja i Niezawodnosc - Maintenance and Reliability 2017; 19 (2): 287-295,
Xu S, Wang H, Li A, Wang Y, Su L. Effects of corrosion on surface characterization and mechanical properties of butt-welded joints. Journal of Constructional Steel Research 2016; 126: 50-62,
Xu T. Fatigue of ship structural details: technical development and problems. Journal of Ship Research 1997; 41(4):318-331,
Yang S et al. Approach for fatigue damage assessment of welded structure considering coupling effect between stress and corrosion. International Journal of Fatigue 2016; 88: 88-95,
Yin Y, Rondin G.Y, Obaia KH, Elwi AE. Fatigue life prediction of heavy mining equipment. Part 1: Fatigue load assessment and crack growth rate tests. Journal of Constructional Steel Research 2007; 63: 1494-1505,
Yin Y, Rondin G.Y, Obaia KH, Elwi AE. Fatigue life prediction of heavy mining equipment. Part 2: Behavior of corner crack in steel welded box section and remaining fatigue life determination. Journal of Constructional Steel Research 2008; 64: 62-71,
You R, Kaewunruen S. Evaluation of remaining fatigue life of concrete sleeper based on field loading conditions. Engineering Failure Analysis 2019; 105: 70-86,
Zaretski A.A. Calculating Life. 2001; Aug./Sept. HOIST.
Prediction of Material Failure Time for a Bucket Wheel Excavator Boom Using Computer Simulation
Andrei Andraș, Sorin Radu, Ildiko Brînaș, Florin Popescu, Daniela Budilică, Eva Korozsi
Analysis of the Dynamic Response as a Basis for the Efficient Protection of Large Structure Health Using Controllable Frequency-Controlled Drives
Nebojša Gnjatović, Srđan Bošnjak, Aleksandar Stefanović
Bucket wheel excavators with a kinematic breakdown system: Identification and monitoring of the basic parameters of static stability of the slewing superstructure
Ivan Milenović, Srđan Bošnjak, Nebojša Gnjatović, Aleksandar Obradović
Eksploatacja i Niezawodnosc - Maintenance and Reliability