A

PROJECT REPORT ON

“Design & failure analysis of solar street light pole under wind load
Effect”
Submitted to the Rashtrasant Tukadoji Maharaj Nagpur University
In fulfillment of the requirement for the award of the degree of

Mater of Technology
In
Mechanical Engineering Design
By

Arti Uttam Lonare

(Enrollment No.:-2015016600651313)

Under the Guidance of

Prof. Name of Guide

DEPARTMENT OF MECHANICAL ENGINEERING

ABHA GAIKWAD-PATIL COLLEGE OF ENGINEERING

Mohgaon, Wardha Road, Nagpur-441108
2019-2020

© AbhaGaikwad-Patil college of Engineering Nagpur

 ABHA GAIKWAD-PATIL COLLEGE OF ENGINEERING
Mohgaon, Wardha Road, Nagpur-441108

CERTIFICATE
This is to certify that the project report entitled

“Design & failure analysis of solar street light pole under wind load
Effect”
Submitted By
Arti Uttam Lonare
(Enrollment No.:- 2015016600651313)

This is a bonafide work carried out by him/her under the supervision of Prof. Name of Guide and
it is submitted towards the fulfillment of the requirement, for the award of the degree of Master of
Technology in Mechanical Engineering Design to Rashtrasant Tukadoji Maharaj Nagpur
University.

Project Coordinator
Project Guide

Head of Department
Vice Principal

Principal
 DECLARATION

We declare that this written submission represents our ideas in our own words and where other's
ideas or words have been included, We have adequately cited and referenced the original sources.
We also declare that we have adhered to all principles of academic honesty and integrity and have
not misrepresented or fabricated or falsified any idea/data/fact/source in our submission. We
understand that any violation of the above will be cause for disciplinary action by the Institute and
can also evoke penal action from the sources which have thus not been properly cited or from
whom proper permission has not been taken when needed.

Name Of Projectee :Arti Lunare

 CERTIFICATE FOR CONDUCT OF EXAMINATION

This is to certify that Viva-voce examination of Arti Uttam Lonare with Project Titled “Design
& failure analysis of solar street light pole under wind load Effect” has been held at Department
of Mechanical Engineering, Abha Gaikwad-Patil College of Engineering, Nagpur.

Date:

Place:

-------------- ------------------

Internal Examiner External Examiner

 Abstract

Light shafts are for quite some time decreased posts and single cylinder structures utilized in
expressways. Wind load is the essential plan power on this structure. In this examination, a
correlation of the quality of steel and FRP light post is made when wind loads follow up on it.
This work makes it conceivable to expand the investigation of a light post by fluctuating shapes
with two materials. Round and hexagonal shapes are considered here. Additionally, the variety
of stress and distortion of the light shaft are checked when a stiffener is set. Stress and
disfigurement results are thought about.

The fatigue behaviour of light pole structures under wind loadings were studied. Fatigue failures
have occurred in luminaire structures as a result of wind-induced vibration under severe
environmental conditions. The increasing number of failures is due to vibration near the
fundamental mode and lack of appropriate damping and motion control. In some sense the
problem has been exacerbated because the majority of fatigue design specifications were
established prior to 2001. As a result, the AASHTO Standard Specifications for Structural
Supports for Highway Signs, Luminaries and Traffic Signals now provide clear design criteria
that incorporate loading conditions and connection detail categories.

ANSYS Workbench was used to complete all of the analysis (ANSYS, 2019). The fatigue
behaviour of light pole structures subjected to 3-sec wind gusts will be studied with particular
emphasis on two critical locations. In particular, emphasis will be placed on hand-hole and
shoe-base connections. The results indicate that, light pole structures with pole thicknesses
larger than 0.375 in are not susceptible to fatigue failure around shoe base connection for the
loading and sizes considered. In addition, by increasing pole thicknesses, the maximum stress
around shoe base decreases. For the case of the hand-hole with different widths, hand-hole with
width of 0.5 in shows better performance as compare to 0.1 in and 1 in width. Finally, the results
indicate that increasing hand-hole thicknesses will reduce fatigue failures around the hand-hole.

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 ACKNOWLEDGEMENT

We express our sincere gratitude towards the faculty members who made this project
work successful.
We would like to express our thanks to our guide Prof. Gaurav Nagdeve for hearted co-
operation and valuable suggestions, technical guidance throughout the project work.
Special thanks to Class In-charge Prof. Dipali Bhoyar and H.O.D. Prof Ritesh Banpurkar for
their kind official support and encouragement.
We would also like to express our deep gratitude towards Principal Dr.P. Kadu and Vice
Principal Prof. Pragati Patil for providing all the facilities and environment for research.
Finally, We would like to thank to all our faculty members of Mechanical
Engineering Department who helped us directly or indirectly to complete this work
successfully.

Arti Lonare

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 TABLE OF CONTENTS

Contents Page no.

Certificate
Declaration
Certificate for Conduct of Examination
Acknowledgment
Abstract i
List of figure ii
List of Table iii
List of Abbreviations iv
List of Publications v

Chapters
1. Introduction 1-4
1.1 Introduction 1
1.2 Loads Affecting Luminaire Structure 2
1.3 Light Pole Components 3
2. Literature Surveys 5-9
3. Design and Calculation 10-20
3.1 Finite Element (FE) Study-Introduction 11
3.2 Geometry 11
3.3 Meshing 13
3.4 Flow Field Calculation 13
3.4.1 Governing Equations 13
3.5 Workflow in Workbench 14
3.6 Geometry and Mesh for FEA Solver 15
3.7 CFD Results 16
4. Fatigue calculation 17-29
4.1 Fatigue Overview 25
4.2 Types of Cyclic Loadings 26
4.3 Types of Results 28
4.4 Fatigue Behavior of Light Pole Structures 29
5. FEA Test Results 30-38

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7. Results and Discussion 39-40
8. Conclusion 41-42
9. Application and Future Scope 43-44
References
Appendix I: Plagiarism Report
Appendix II: Publish Papers, Publications Certificates
Appendix III: Course work Completion Certificate by Guide.
Appendix IV: Bill Material

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 LIST OF TABLE
3.1 Model (C4, D4) > Mesh 13
5.1 Force Reaction 36
6.1 Result of model 40
7.2 Gravity Condition 42

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 LIST OF FIGURES
1-1 Frame work of Solar Light Pole 3
1-2 Frame work of Solar Light Pole base 3
1.3 CAD Model of Solar Street Light 4
3-1, Fluid geometry used for Finite Volume Method 12
3-2, Top view of the geometry for CFD 12
3-3, Steps used for modelling light poles in ANSYS Workbench 15
3.4 Output – CFD Wind Test – 80Km Per Hr. - Pressure 16
3.5 Output – CFD Wind Test – 80Km Per Hr. - Pressure 17
3.6 Output–CFD Wind Test – 80Km Per Hr. Turbulence Kinetic Energy 18
3.7 Output – CFD Wind Test – 80Km Per Hr. Velocity 19
3.8 Output – CFD Wind Test – 80Km Per Hr. Velocity 20
3.9 Output – CFD Wind Test – 80Km Per Hr. Velocity 20
3.10 Output – CFD Wind Test – 80Km Per Hr. Velocity 21
3.11 Output – CFD Wind Test – 80Km Per Hr. Velocity 21
4-1, Constant Amplitude Load Fully Reversed 27
4-2, Constant Amplitude Zero-Based 27
5.1 Material Details 31
5.2 Assembly Details 32
5.3 Pre- Processing – Gravity Test 33
5.4 Input & Pre- Processing - Load Test 34
5.5 Output – Load Test Total Deformation 34
5.6 Output – Load Test Elastic Strain 35
5.7 Output – Load Test Von-Mises Stress 35
5.8Output – Load Test force rection 36
5.9 Output – Load Test Safety Factor – Stress 37
5.10 Output – Load Test Fatigue Life 37
5.11 Output – Load Test Fatigue Safety Factor 38

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 CHAPTER – I

INTRODUCTION

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 INTRODUCTION

Solar energy is the technology used to harness the sun's energy and make it useable. The
technology produced less than one-tenth of one percent of global energy demand.
Many are familiar with so-called photovoltaic cells, or solar panels, found on things like
spacecraft, rooftops, and handheld calculators. The cells are made of semiconductor materials
like those found in computer chips. When sunlight hits the cells, it knocks electrons loose from
their atoms. As the electrons flow through the cell, they generate electricity.

On a much larger scale, solar-thermal power plants employ various techniques to concentrate
the sun's energy as a heat source. The heat is then used to boil water to drive a steam turbine
that generates electricity in much the same fashion as coal and nuclear power plants, supplying
electricity for thousands of people.

As required by their capacity and arrangement in the by and large open encompassing, wind
stacking is the essential plan power on these structures. Due to lightweight slim design, the light
shafts are incredibly adaptable with normal major common

frequencies. The posts must be intended to limit vibration and redirection. These days
fashioners pick steel and composite FRP utilized for making light posts. Steel posts are most
normally utilized decreased shafts’ is lightweight and consumption obstruction. Strands are two
kinds of common and manufactured fibre. Engineered strands are usually utilized in structures
and ongoing examinations.
Fatigue failures take place due to the repeated application of variable stresses that are much
lower than the stress required to cause failure during a single application. Fatigue failures result
from repeated loadings and the resulting stress cycles. Each effective stress cycles above the
active threshold causes a certain amount of damage. The most distinguishing locations of
fatigue failures in components are at areas of stress concentrations such as welds, notches, holes
and changes in section. Typical areas that may exhibit fatigue cracking in sign, signal and
luminaire structures are at welds, anchor bolts, hand-hole and base connections.

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1.1Loads Affecting Luminaire Structure
(AASHTO) has distributed detail for auxiliary backings for roadway signs, illuminators and
traffic Signals that distinguish four kinds of wind-prompted loadings to be considered in the
structure, including Galloping, Vortex shedding, Natural breeze blasts, and Truck-actuated
breeze blasts.

Running and vortex shedding is aeroelastic wonders brought about by the activity of wind and
basic vibration. Dashing actuated vacillation essentially happens firm, delicately damped
structures with non-balanced cross-segments. Vortex shedding regularly happens during
consistent uniform streams and makes a thunderous vacillation in a plane ordinary to the course
of stream. Jogging results from uneven intermittent powers, while vortex shedding is brought
about by the shedding of vortices in the wake behind of basic component.

Characteristic breeze blast emerges from alters in speed and course of wind current. Truck-
incited wind blast is characterized as the section of trucks beneath cantilevered bolster
structures bringing about actuated blast load on the front region and underneath the individuals.
The impact of these heaps is generally impressive in cantilevered sign-bolster structures which
have an enormous front territory. Dissimilar to running and vortex shedding emerge in steady
sufficiency, the plentifulness of the reaction to normal breeze blasts and truck-instigated wind
blasts are variable.

It is generally believed that luminaire structures are not subjected to Galloping and Truck-
induced wind gusts but, Vortex shedding and Natural wind gusts are the major cause of fatigue
damage in luminaire structures.

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1.2Light Pole Components

A cantilevered light post structure comprises of the accompanying components: Pole shaft,
base, stay jolts, hand-opening and luminaire as appeared in Figure 1-1. A typical basic detail
that joins the base and hand-gap to the post shaft is filet-welded associations. The base of the
round cylindrical shaft is embedded into the base that contains a roundabout gap. Filet welds
are put between the shaft and base as appeared in Figure 1-2. The outside filet weld is named a
classification E' weariness detail and is a zone of configuration worry in light post structures.

Fig.1-1 Frame work of Solar Light Pole

Fig.1-2 Frame work of Solar Light Pole

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Fig 1.3 CAD Model of Solar Street Light

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 CHAPTER – II

LITERATURE REVIEW

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 LITREATURE REIVIEW

Luminaire, traffic signals and sign structures are generally utilized for traffic control
everywhere throughout the world. There are various sorts of luminaire structures yet the vast
majority of them comprise of a vertical shaft with or without a cantilevered arm for signs or
signs.

Light post structures are adaptable because of their long-range thickness and moderately little
cross-sectional territory. This may cause or result in low regular frequencies for the initial a few
modes. In addition, gave damping has not been enlarged, the damping in luminaire structures
is low, roughly around one percent of basic damping.

Thus, luminaire structures might be helpless to exhaustion disappointment under wind stacking.
During the previous three decades, weariness harm has happened in luminaire structures.
Exhaustion is confined auxiliary harm that happens when a material or part is exposed to cyclic
stacking. Harm may happen regardless of whether the ostensible greatest anxieties esteem is
not exactly a definitive ductile pressure limit or underneath the yield pressure breaking point of
the material.

C.W. Chien and J. J. Jang (Taiwan Ocean University)

This paper gives the contributions of high natural frequency components are obtained by
Eigenvalue analysis. The method to check vortex resonance and galloping for higher-order
modes is also presented. Because of turbulent winds in the atmosphere and characteristics of
the irregular bluff bodies of the structures are complicated to deal with, a mathematical model,
with interactive wind and structure, is still impossible at present.
This study includes four parts:
(1) a survey of geometric configurations and shape factors;
(2) along with the wind and across-wind response analysis;
(3) develops criteria for WRD; (wind resistance design);
(4) provides case application for WRD procedures.

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Mal Thomas and Gary Noyes-Brown

This paper describes the investigations that were undertaken and the recommended
modifications that would reduce the stress concentration in the pole mast, and hence extend the
pole life. The 28 light poles at the freeway interchange were all of the similar construction.
figer1shows the typical luminary’s arrangement at the top of the light poles, and shows a typical
light pole base, with significant features being the access opening, the gusset plates, base plate
anchor bolts and grout. Inspections carried out by Vic Roads identified cracking in 27 of the 28
high mast light poles at the freeway interchange. All cracking was in the light pole mast, at the
tip of the gusset stiffeners. The base plates were not fully grouted; poor grouting has been
known to contribute to damages of anchor bolts in other light poles and sign. Bolts need to be
checked for stress due to tension and shear, however additional stress due to bending needs to
also be considered if the bolts have a free length due to insufficient grout.

Counsell Taplin (AASHTO-2006)

In this paper, the American Association of State Highway and Transportation Officials
(AASHTO) have commissioned significant research in the USA in the last five years.
Culminating in the AASHTO “Standard Specifications for Structural Supports for Highway
Signs, Luminaries and Traffic Signals” (AASHTO 2006). This standard provides a tool for the
design of light poles and sign gantries. This research by AASHTO has been undertaken in
response to the failure of numerous light poles in the USA. For example, in Iowa in 2003, a 43-
meter-high light poles collapsed (see in fig.1) prompting an extensive investigation into this
type of structure.

Creamer (1979), Fatigue Loading of Cantilever Sign Structure (1979)

This research was carried out to develop a method for checking the fatigue of cantilever
highway sign structures for truck-induced gust loading. It was concluded that truck-induced
gusts can produce significant sign response and a large number of stress fluctuations. Moreover,
a peak pressure of 1.23 psf with period of 0.375 sec is noteworthy characteristics of truck-
induced pressure plusses (Creamer, 1979).

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Fisher and colleagues (1981), Steel Through Plate Socket Connection Tests

Fisher, et al was the first group which studied fatigue behavior of standard light poles. Fatigue
tests were conducted on a series of poles fabricated from A283 Grade D steel built by Ameron
Pole Products Division having standard 45º equal weld legs and a series fabricated from A595
steel built having unequal fillet weld legs was evaluated as well. Two additional specimens
from Ameron were fabricated separately for comparison purposes. Poles built by Valmont were
designated as V1-V6, poles build by Ameron were designated as A1-A6 and the two additional
specimens were designated as A7 and A8. Fatigue tests confirmed that poles with equal 45º
fillet weld legs had a fatigue strength less than Category E’. However, poles with unequal fillet
weld legs had fatigue strength equal to Category E. Fatigue cracks appeared at the toe of the
welds at the base of the signal arm and at the base of the pole at approximately same number
of cycles. It was observed that when poles were galvanized, small fatigue cracks were hard to
identify. The galvanized coating allows large cracks to form before the coating breaks. As a
result, most of the fatigue life was exhausted before cracks were identified. In this project the
issue of base flexibility was also related to the fatigue results (Fisher et.al 1981).

Gilani (1997), Fatigue Life Evaluation of Steel Post Structure

This paper summarizes a research effort conducted for the California Department of
Transportation (CALTRANS) after the collapse of a Changeable Message Sign (CMS)
structure. The research included both field and analytical studies. Field measurements were
undertaken to quantify the natural frequencies of vibration and structural characteristics. The
analytical study was carried out using FE analysis to estimate the stress distributions around
access holes and within base plates. The experimental and analytical investigations revealed
that a conduit hole was a significant source of fatigue concern in CMS structures. This report
also briefly evaluated the wind loading experienced by CMS structures. Vortex shedding was
considered possible although it would occur at a low velocity (5 mph). At low wind speeds
stress ranges would not be of any practical significance (Gilani et.al 1997).

Kaczinski (1998), NCHRP Report 412

Many structural engineers believed that the design guidance in AASHTO should be improved
with respect to fatigue. NCHRP project 412 was proposed to develop guideline for fatigue
design of sign, signal and luminarie structures. The magnitude of stress ranges in many cases
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is critical and causes fatigue cracks. Among the 36 states which responded to a survey,
approximately 50% had problems with wind-induced vibration of cantilevered support
structures. The report indicates that truck and natural wind-induced vibrations were responsible
for the accumulation of fatigue damage in structures that have been in service for a number of
years.

The report discusses aerodynamic studies and aero elastic studies performed on full scale
cantilever sign structures. These studies indicate that cantilever structures with signal
attachments are susceptible to galloping and become worse when back plates are added to the
signal attachments. Moreover, vortex shedding does not need to be taken in to account for wind
velocities less than 5 mph. Finite Element Analyses were conducted to calculate wind pressures
on cantilever support structures during vortex shedding, galloping, natural wind and truck
induced vibrations for both static and dynamic approaches.

It was recommended that only cantilever support structures not having attachments and having
lock-in velocities greater than 10 mph be considered susceptible to vortex shedding. Final
recommendations suggest that dynamic and static analyses should be conducted to determine
and estimate equivalent static load ranges for the four load types (Kaczinski et.al 1998)

Azzam (2006), Fatigue Behaviour of Aluminium Light Pole Structures

This research was conducted to develop fatigue study on full-scale welded aluminium light pole
structures. Fatigue tests were conducted on light poles containing both shoe base and through
plate socket connection details order to study the fatigue behaviour and determine lower bound
resistance suitable for design in terms of S-N curves. Fatigue tests revealed relatively low
strengths for the through plate socket connection as compared to the shoe base details.
Parametric studies revealed that residual stresses play an important role in the behaviour of light
pole structures. Moreover, attempts to stiffen through plate socket connections using triangular
plate stiffeners resulted in longitudinal stresses at the tip of the stiffeners for short stiffeners
that contradict AASHTO specification fatigue categories for light pole structures. (Azzam,
2006)

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CHAPTER – III

DESIGN AND
CALCULATION

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 FINITE ELEMENT MODELING

3.1 Finite Element (FE) Study-Introduction

Finite element models for several parametric studies were constructed and analyzed in order to
gain insight into the behaviour of the light pole structures during wind loads (specifically, wind
gust). Parametric studies were conducted to increase understanding of the important geometric
features and their influence on local stresses that derive the fatigue response specifically; the
hand-hole reinforcement width, hand-hole geometry and shoe base connection were examined.
ANSYS Workbench was used to complete all of the analysis (ANSYS, 2012).

3.2 Geometry

The light pole geometry was created in Design Modeler (DM) in three dimensions (3-D) has
all details from measurements and engineering drawings. A box has been added around the
model to include the environment around the pole. Upstream of the pole has a dimension of
15R (R is the radius of the pole). Downstream has been expanded to 60R. On sides and top the
distance of 15R was considered (Anderson, J.D, 2006).

The pole body has been subtracted from the fluid (air) region in this part. The geometry has one
inlet and outlet and three symmetric walls on the sides and one wall at the bottom. Symmetric
walls generate no friction on the air (fluid) as it has zero gradients for velocity and other
parameters normal to its plane. As such, there is no need to model an infinite surrounding.
Figure 3-1 shows the geometry and Figures 3-2 and 3-3 show it in top and side view. The
geometry is sliced with different cut planes to have additional control on mesh size. A finer
mesh is applied close to the pole to capture velocity and pressure gradients more exactly.

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Opening all other Side
Atmospheric Pressure : 101325
Pascal
Inlet Air Flow –
80km per Hr.

Figure 3-1, Fluid geometry used for Finite Volume Method

Figure 3-2, Top view of the geometry for CFD (Computational Fluid Dynamics)

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3.3 Meshing

The flow domain shown in Figures 3-1 and 3-2 is meshed for finite volume calculations
conducted via the ANSYS Fluent code. There are different methods to generate a mesh in
ANSYS meshing. Here, the mesh is generated by using assembly meshing (cutcell method).
Assembly meshing or cutcell generates a cartesian mesh so the domain is meshed by hexahedral
elements. Inflation has been added to cover the walls of the pole. Inflation helps to capture the
velocity gradients and pressure distribution close to the pole with more resolution. Mesh
orthogonal quality is always above 0.08 to avoid convergence issues in solution. Mesh is shown
in Figure 3-4 and Figure 3-5 (in 2-D and 3-D) with a cut plane which passes through the pole.

Table 3.1 Model (C4, D4) > Mesh

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3.4 Flow Field Calculation

In this section, we first describe the Navier-Stokes flow equations and the numerical scheme
for solving these equations using the fluid dynamics code from ANSYS Fluent. We also present
our mesh-independence study.

3.4.1 Governing Equations

A steady state, turbulent, incompressible model has been adopted for the flow regime inside the
domain. The finite volume method (Patankar 1980) implemented in The Fluent code is used to
solve continuity and conservation momentum. Since it would be computationally prohibitive to
model the often very small scale and high frequency fluctuations in fluid velocity seen in
turbulent flow in production environments, time averaged methods of simulating turbulence
effects have been derived. In these models, terms are introduced to simulate the average
turbulent flow field, so that the small-scale turbulent behaviour does not have to be solved
explicitly by the Navier-Stokes equations. Instead, transport equations are solved in order to
bring the model to closure and model the full range of turbulent flow scales. In the case of the
k turbulence model, the values of k, the turbulent kinetic energy, and ε epsilon, the
turbulence dissipation rate must be determined. These so-called Reynolds-average Navier-
Stokes (RANS) turbulence models significantly reduce the processing power required and make
turbulence modelling practical for a wide range of turbulent flow problems. In turbulence
models that involve Reynolds averaging, the exact Navier-Stokes flow solution is broken down
into its varying and time averaged components.

3.5 Workflow in Workbench

Workbench is relatively new and may be used to connect different solvers. The Computational
Fluid Dynamics (CFD) solver in ANSYS is based on a Finite Volume Method. The used
workflow is shown here.

Block A in Figure 3-8 is the geometry block in Design Modeler. This geometry was discussed
in Figure 3-1. It contains a flow domain around the pole. Block B contains mesh information
which was discussed in Figures 3-3 and 3-4. By using another wire, information of Block B
was passed to Block C which is the CFD solver. After solving Fluid Flow the pressure
distribution on walls of pole is transferred as an input data to Block D which is the FEA solver
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and called ANSYS Structural. Please notice that the mesh in CFD and Mechanical can be totally
different. Behind the scene ANSYS data mapping takes care of only differences. It does an
interpolation between the data from the CFD solver to the FEA solver. The geometry of the
pole for FEA analysis is considered in Block E. This geometry will be discussed in the next
paragraph. The information associated with this geometry is passed to Static Structural for
solution. Meshing and other settings for FEA solver are in D4 which is called Model.

Figure 3-3, Steps used for modelling light poles in ANSYS Workbench

3.6 Geometry and Mesh for FEA Solver

The geometry is modelled based on measurements of parts and engineering drawings. The
geometry is shown in Figure 3-9 shows slices which used for mesh generation. By sliding the
geometry, it is divided in to sweep able bodies which can have a hexahedral mesh and reduce
number of mesh elements. This is important as ANSYS Mechanical does not scale well
(ANSYS-FLUENT is totally scalable and you can use as many CPUs as you needed to improve
the speed and reduce the turnaround of simulation).

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3.7 CFD Results

The imported load from Fluent will be used in FEA analysis. The CFD results are shown in this
section. In Figure 3-11, velocity contours on y-plane are shown from distance of pole bottom.

Output – CFD Wind Test – 80Km Per Hr. - Pressure

Fig 3.4 Output – CFD Wind Test – 80Km Per Hr. - Pressure

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Output – CFD Wind Test – 80Km Per Hr. - Total Pressure

Fig 3.5 Output – CFD Wind Test – 80Km Per Hr. - Total Pressure

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Output–CFD Wind Test – 80Km Per Hr. Turbulence Kinetic Energy

Fig 3.6 Output–CFD Wind Test – 80Km Per Hr. Turbulence Kinetic Energy

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Output – CFD Wind Test – 80Km Per Hr. Velocity

Fig 3.7 Output – CFD Wind Test – 80Km Per Hr. Velocity

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Output – CFD Wind Test – 80Km Per Hr. Velocity – X-Y-Z

Fig 3.8 Output – CFD Wind Test – 80Km Per Hr. Velocity – X

Fig 3.9 Output – CFD Wind Test – 80Km Per Hr. Velocity – Y

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 Fig 3.10 Output – CFD Wind Test – 80Km Per Hr. Velocity – Z

Output – CFD Wind Test – 80Km Per Hr. Velocity

Fig 3.11 Output – CFD Wind Test – 80Km Per Hr. Velocity
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Fig 3.12 Output – CFD Wind Test Stream line – 80Km Per Hr. Velocity

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Output – CFD Wind Test – 80Km Per Hr. Velocity

Fig 3.13 Output – CFD Wind Test – 80Km Per Hr. Velocity

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CHAPTER – IV
FATIGUE
CALCULATION

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 FATIGUE

4.1 Fatigue Overview

Fatigue is a cumulative damage process caused by the repeated loading. Fatigue may result
from the repeated application of stress levels much lower than the tensile strength of a given
material. Fatigue is typically divided in to two categories;

1) Low-cycle fatigue

2) High-cycle fatigue

High-cycle fatigue occurs when the number of cycles (repetition) of the load is relatively large
(e.g., 1e4 – 1e9). As a result, the stresses are usually low compared with the material’s strength.
Stress-Life approaches are used for high cycle fatigue and cyclic strains occur mostly in the
elastic range. These are global stresses. Locally, stresses to cause damage are plastic.

Low-Cycle fatigue occurs when the number of cycles of the load is relatively low. Plastic
deformation often accompanies low-cycle fatigue, which explains the relatively short fatigue
life (N< 10000). Strain-Life approaches are best suited for low-cycle fatigue evaluation. The
focus of this study is high-cycle fatigue or Stress-Life. In the vast majority of cases, light poles
and similar structures are designed for infinite life. In this Chapter, Fatigue behavior of light
poles under three- second wind gusts will be studied.

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4.2 Types of Cyclic Loadings

Static stresses are analysed using calculations for a single stress state. However, fatigue damage
occurs when stress at a point changes over time. There are essentially four classes of fatigue
loading. These classes are described as follow;

1) Constant Amplitude, Proportional Loading

2) Constant Amplitude, Non-Proportional Loading

3) Variable Amplitude, Proportional Loading

4) Variable Amplitude, Non-Proportional Loading

When minimum and maximum stress levels are constant, constant amplitude loading results
otherwise, the loading is known as a variable amplitude or non-constant amplitude. The second
identifier, proportionality, describes whether the changing load causes principal stress axes to
change. If the principal stress axes do not change, then the loading is proportional. If the
principal stress axes change, then the cycle cannot be continued simply and it is non-
proportional loading. Each Stress-Life and Strain-Life approach includes variety of loadings.
Stress-Life includes; a) Constant Amplitude, Proportional Loading, b) Variable Amplitude,
Proportional Loading and c) Constant Amplitude, Non Proportional Loading. However, The
Strain-Life approach only contains Constant Amplitude, Proportional Loading. Each type of
loading describes shortly as follow:

Constant Amplitude, Proportional Loading is constant amplitude because only one set of finite
element stress results along with the loading ratio is required to calculate alternating stress and
mean values. The loading ratio is defined as the ratio of minimum

to maximum load. Common types of constant amplitude loading are fully reversed (apply a
load, then apply an equal and opposite load for a load ratio of -1) and zero based (apply a load
and then remove it; the load ratio is zero). Therefore, at a single set of finite element results can
determine critical fatigue locations. For a better understanding, constant amplitude load fully
reversed and zero based types are shown in Figure 4-1 and Figure 4-2 respectively

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 Figure 4-1, Constant Amplitude Load Fully Reversed

Figure 4-2, Constant Amplitude Zero-Based

Constant Amplitude, Non-Proportional Loading, implies that the loading is of constant

amplitude but the principal stress and strain axes can change between two load sets. The critical
location may occur in a location that is not easily identifiable. Common types of non-
proportional loadings can describe as follow; 56
a. Alternating between two different load cases such as bending and torsional loads
b. An alternating load superimposed on a static load
c. Nonlinear boundary conditions

Variable Amplitude, Proportional Loading; In this case, the load ratio changes over time and it
requires one set of finite element results. Fatigue critical locations may be determined by
looking at a single set of finite element result. However, the damage accumulation caused by
fatigue loading may not easily be determined. Total damage may be calculated through
cumulative damage rules such as Miner’s rule and Rainflow counting. Cycle counting is used
to simplify complicated load histories to a number of constant amplitude test data. Results from
cycle counting are commonly summarized in a histogram format. The ANSYS Fatigue Module
uses a “quick counting’ technique to reduce runtime and memory.

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Variable Amplitude, Non-Proportional Loading, in this type of loading the variety of stress
cases included has no relationship to one another. Fatigue critical locations are easily
determined life is not determined. In addition, the combination of loads which caused damage
is not obvious. As a result, a multiaxial critical plane method and advanced cycle counting
techniques are required.

4.3 Types of Results

Both Stress-Life and Strain-Life are considered for all cases. In all cases, the Stress-Life
approach is better suited for evaluation of luminaire structures. Therefore, only Stress-life
results are discussed. Types of Fatigue results conducted in this research are listed as below:

a) Fatigue Life
b) Fatigue Damage
c) Fatigue Safety Factor
d) Stress biaxiality
e) Fatigue Sensitivity

Fatigue Life is defined as the number of stress cycles which an element under cyclic loadings
can resist before failure. Comparative results are shown using ANSYS Workbench for different
cases. The resulting contour plots shows the available life for a given fatigue analysis. If loading
is constant amplitude, the results provide the number of cycles. However, if loading is variable
amplitude, results describes the number of loading blocks until failure.

Fatigue Damage is defined as the design life divided by the available life. For fatigue damage,
values greater than one indicate failure before the design life is obtained.

Fatigue Safety is a factor of safety with respect to a fatigue failure at a given design life. The
maximum factor of safety is equal to 15 and values less than one describes failure before the
design life.

Biaxiality is defined as the smaller principal (magnitude) divided by the larger principal stress
with the principal stress nearest to zero ignored. A biaxiality of zero refers to uniaxial stress, a
value of 1 refers to a pure biaxial state and a value of -1 refers to pure shear.

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Fatigue Sensitivity describes how the fatigue results vary as a function of loading at the critical
location in the model. Sensitivity may be calculated for life, damage or the safety factor. The
life sensitivity for all of the cases is investigated by changing the load percentage. A value of
100% corresponds to the life at the current loading.

4.4 Parametric Study of Fatigue

A parametric study was conducted on luminaire structures by using the commercially available
finite element code (ANSYS Workbench 14.5). This study provides insight into the nature of
fatigue critical areas, around the weld toe adjacent to both the hand-hole and base. In addition,
the influence of geometry changes on the local stress fields, fatigue life, damage, factor of safety
and fatigue sensitivity is studied. These Models dimensions take from HAPCO, a well known
firm specializing in manufacture of light poles. A light pole structure shown in Figure 4-3 is
used as the basis for finite element analyses

Figure studies 4-3, Shoe base connection dimensions for specimens used in fatigue and finite
element

4.5 Fatigue Behaviour of Light Pole Structures

In the following subsections, the fatigue behavior of light pole structures subjected to 3-sec
wind gusts will be studied with particular emphasis on two critical locations. In particular,
emphasis will be placed on hand-hole and shoe-base connections

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 CHAPTER – V
FEA Test Results

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 FEA Test Results
1. Gravity Test
2. Load Test

Input & Pre- Processing

Geometrical Preparation (STEP, IGES or Parasolid Format)

Material Details
• Solar Panel – Glass & Aluminum
• LED Light - Glass & Aluminum
• Pole – Standard Material (Aluminum)

Fig 5.1 Material Details

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Input & Pre- Processing

Mesh Details
• Node: 414905
• Element: 77759

Assembly Details
• Light and Pole – Slide & Bolt Joint
• Solar Panel and Pole – Slide & Bolt Joint
• Pole Base – Concrete Bolt Joint

Fig 5.2 Assembly Details

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Gravity Test Results

Pre- Processing – Gravity Test

Fig 5.3 Pre- Processing – Gravity Test

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Input & Pre- Processing - Load Test

Fig 5.4 Input & Pre- Processing - Load Test

Output – Load Test Total Deformation

Fig 5.5 Output – Load Test Total Deformation

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Output – Load Test Elastic Strain

Fig 5.6 Output – Load Test Elastic Strain

Output – Load Test Von-Mises Stress

Fig 5.7 Output – Load Test Von-Mises Stress

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Output – Load Test
- Force Reaction

Fig 5.8 Output – Load Test force rection

Table 5.1 Force Reaction

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Output – Load Test Safety Factor – Stress

Fig 5.9 Output – Load Test Safety Factor – Stress

Output – Load Test Fatigue Life

Fig 5.10 Output – Load Test Fatigue Life

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Output – Load Test Fatigue Safety Factor

Fig 5.11 Output – Load Test Fatigue Safety Factor

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CHAPTER – VI
RESULT AND
DISCUSSION

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 Result Discussion

This project has considered some of key factors associated with the design of HMS due to the
effects of wind loading. Then major findings are summarized as follows. According to the
results of this research, the projected area is more critical in this aspect. As for the intensity of
wind excitation increases with increasing of aspect ratio (height-to-width). However, it
decreases with increasing of structure damping. Consequently, the results of this research
indicate that HMS is quite different from the tower structure. Furthermore, the body of the tip
plays a major role in design.

S . Gravity Test Load Test

Values Unit
No Max. Min. Max. Min.

1. Total Deformation 15.4190 0 14.953 0 mm

2. Elastic Strain 0.0004294 1.55e-9 0.00067886 3.9779e-9 mm/mm

3. Equivalent Stress 20.685 6.75e-5 48.082 8.80e-5 MPa

4. Reaction Force 1048.3 1048.3 1048.3 1048.3 N

5. Stress Safety 15 13.537 15 5.8234 -

Factor

6. Fatigue Safety 15 4.001 15 1.7208 -

Factor

7. Fatigue Safety Life 1e+8 1e+8 1e+8 1e+8 Cycle

Table 6.1 Result of model

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CHAPTER – VII
CONCLUSION

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 Conclusion

• Maximum Stress Observer in the structural is based on the Condition's which is

tabulated Below:
• All Component Stress are within the yield limit the condition of 80km/hr. wind speed
time. So, we conclude the structure is adequately stable for load.
• The Maximum stress value which we got from the analysis is 48.082MPa Which is Way
Lower then the maximum allowable Stress limit for this Material Aluminum. This value
is acceptable as per the Standard.

S. Conditions Safe Yield Maximum Notes

No Stress (MPa) Stress (MPa)

1. Gravity Test Only 250 20.685 Safe

2. Gravity + Load Test 250 48.082 Safe

Table 7.2 Gravity Condition

Failures caused by fatigue cracking often occur around welded structural details, some welded
details include the light pole support base and hand-hole. Many of these failures are caused by
wind-induced vibration, resulting in various applied stress cycles at the weld toe. This report
analysed the application of wind forces and specifically wind-gusts at the weld toes of light
pole structures. Predicting fatigue life, damage, stress and strain were the goals of this study.
Based on this parametric study, the following results were obtained:

Based on parametric studies, the fatigue strength of light pole structures may be improved by
increasing pole thicknesses. An increase in pole thickness from 0.188 in to 1 in decreased Total
deformation and the maximum equivalent stress adjacent to the weld toe by at least 42% in all
cases evaluated.
An increase in hand-hole reinforcement width did not significantly change the maximum
equivalent stress in the hand-hole adjacent to the weld toe.

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 CHAPTER – V
APPLICATION AND
FUTURE SCOPE

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 RECOMMENDATIONS FOR FUTURE WORK

1) Full scale fatigue tests on Aluminum light pole structures should be done to validate
FEM results.
2) Long term monitoring sign/signal structures to validate pressure and load
recommendations for vortex, galloping, truck induced and wind load effects.
3) Unsteady analysis in ANSYS Fluent to get more accurate results in modeling wind-
gusts

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CHAPTER – VI
REFERENCES

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 REFERENCES

American Association of State Highway and Transportation Officials (AASHTO)

(2001) Standard Specifications for Structural Supports for highway signs, Luminaries
and traffic signals, 4th Ed., Washington, D.C

American Association of State Highway and Transportation Officials (AASHTO)

(2004) Standard Specifications for Structural Supports for highway signs, Luminaries
and traffic signals, 4th Ed., Washington, D.C

American Society of Civil Engineers (ASCE 7-1995) Minimum Design Loads for
Buildings and Other Structures.

ANSYS Workbench (14.5)

Anderson, J.D., "Fundamentals of Aerodynamics", 2nd Ed., Ch. 3: pp. 229.

Azzam, D., Menzemer, C.C. (2006). “Residual stress measurement of welded aluminum
light pole supports.” American Society of Civil Engineers, Journal of Structural
Engineering (Accepted February 2006).

Bannantine, J. A., Comer, J.J., Handrock, J. L. (1990). Prentice Hall New Jersey.

Basquin, O. H. (1910). “The exponential law of Endurance Tests” Am. Soc. Test.
Materials Proc, Vol, 10, pp. 625-630.

Bauschinger, J. (1886). Mitt. Mech-Tech, Lab Munchen, Vol.13, No.1 1886.

Brooks, C. R., Choudhury, A. (2002). “Failure Analysis Engineering

Materials”McGraw-Hill.

Creamer, B. M., Frank, K. H., & Klingner, R. E. (1979). Fatigue Loading of

Cantilever structures from Truck Wind Gusts. Austin, Texas: Texas State Department
of Highways and Public Transportation; Transportation Planning Division P. O. Box
5051.
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Davenport, A.G., The Spectrum of Horizontal Gustness Near the Ground in High
Winds, Quarterly Journal, Royal Meteorological Society, Vol. 87, London, 1961.

Downing, S. D., and Socie, D. F. (1982). “Simple Rainflow Counting

Algorithms,” International Journal of Fatigue, Vol. 4, No. 1, pp. 31-40.

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