Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd ANALYSES OF SHIP STRUCTURES USING ANSYS Suman Kar, D.G. Sarangdhar & G.S. Chopra SeaTech Solutions International (S) Pte Ltd E-Mail:[email protected] Abstract This paper describes the use of ANSYS Structural in the simulation of the complex ship structure and the various loading conditions that a ship experiences during its operation. The ship, during operation experiences complex loading conditions, which is generally divided into few categories: Linear Static and Dynamic Loads, Thermal Loads and Complex Non-Linear Dynamic Loads. Generally the loading on the ship is a combination of some or all of the load categories mentioned above, depending on the type of the ship. The first part of the paper is dedicated to Static and Linear Dynamic Analysis and its combinations. This is used to analyze merchant and Naval ships. Static Analysis is usually done to find the overall strength of the structure. For this, in addition to hydrostatic and hydrodynamic loadings from exterior, the local loads due to ballast tanks; cargo loads etc are also considered. In the domain of Dynamic Analysis, Vibration Analysis (Free and forced) is done for all ships/components to check if the structure is dynamically stable or not. The natural frequencies of the structure are compared with the forcing frequency to check for resonance. The second part of the paper deals with Complex Non- Linear Static and Dynamic Analysis, which is either used for research or for analysis of Ship local components / regions. These analysis includes analysis of Forward part of the ship due to slamming loads, Analysis of Floating structures due to underwater Explosions, transient dynamic analysis of heli-decks due to crash landing of helicopters etc and Ultimate strength Analysis of stiffened ship panels and Midship sections of various ships. Both Geometric and Material Non-Linearity are extensively incorporated to analyze these components/regions, which gives near accurate results. Ships, which carry LNG, require a Thermal Analysis to be done to check the structural integrity of these LNG Carriers. Hence for these ships ANSYS is used for Thermal Analysis. Keywords: Ships, ANSYS Mechanical, Static Analysis, Vibration Analysis, Transient Dynamic Analysis, Ultimate Strength Analysis, Thermal Analysis 1. Introduction Provision of ‘adequate’ strength in a ship at a reasonable cost, has always been one of the most challenging task for the ship designers. Over the years the classification societies have been providing the necessary standards to ensure the adequacy of strength against all demands that can be envisaged during service life of the ship. Earlier, these formulations were largely based on experience of good ships and the scantling requirements were given in simple tabular forms based on few basic parameters like main particulars of the ship. Subsequently, from around 1970, there was significant change in the class rule formulations, wherein the requirements were specified by various formulae for environmental loads and allowable stresses based on simple principles of structural mechanics. Though these formulations were more scientific, the designer did not explicitly know the safety margins in the formulation and inherent assumptions made, so it was difficult to use such formulations for a novel design. In the last two decades there has been a rapid development in the fields of hydrodynamics and structural analysis. The advanced methods developed now provide a better understanding of environmental loads (Demand) and strength of ship (Capacity). As these methods became more and more mature, providing reliable tools for structural optimization, it was only logical that they were incorporated in the classification rules for ship and components design and analysis. 1 Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd 2. Advanced methods for assessment of structural strength Behavior of ship in a seaway has been traditionally assessed by means of sea keeping model tests. The procedures for model testing and subsequently scaling of the results for actual ship size are now well established and are quite reliable. However one of the drawbacks with the experimental methods is the large cost associated with it. With the advancement in the structural and hydrodynamics theories today it is possible to predict the ship behavior to an acceptable reliability by means of numerical simulation. Once the sets of various realistic loads applicable to a vessel are determined, the combined effects of these loads are assessed to determine the overall strength of the ship structure. Advanced methods based on Finite Element Method are best suited to analyze complex structures in three dimensions. With the advancement of Numerical analysis methods and availability of computing facility at affordable costs, use of such methods provides more reliable and direct assessment. 3. Ship and Allied Structures Ships and its components are generally assessed for Strength and Vibration under normal operation and Strength assessment under critical loading condition like collision or underwater explosion etc. Assessment of strength is now a days based on ‘Direct Strength Analysis’ which eliminates any error in judgment, which may arise out of several assumptions that otherwise have to be made regarding the interaction between several structural members. The method takes into account the effect of bending, shear, and axial and torsional deformations all together. Thus it is very useful for larger Ships with complex structural arrangements and large variety of cargo / ballast loading conditions. There major aspects of structural analysis are (i) Creation of structural model for FE analysis (ii) Calculation of loads and transfer to the structural elements (iii) FE analysis (iv) Extraction of results, checks and report. 3.1 Modeling The complex ship structure, which may vary from 100 to 300 meters in length: 7 to 30 meters in breadth and 5 to 30 meters in depth, is modeled completely using ANSYS Pre processor. The plates are modeled using Shell 63/ Shell 43/Shell 181 Elements. The stiffeners are modeled using Beam 4/Beam 44/ Beam 188 Elements. All the pillars are modeled using Pipe elements and all other structural masses are modeled using Mass elements. The modeling of the entire ship structure with all details consumes lot of time and is usually cumbersome. Hence ANSYS macros and APDL’s are extensively used in modeling. This reduces lot of modeling time and manual errors. Ones the model is completed, each of the plates, Stiffeners, Pipes and masses are individually selected and the real constants calculated and inputted in the tabular form to model each component of the structure with complete accuracy. This process is also automated at times with the use of ANSYS macros and APDL’s 3.2 Meshing After the complete structure is modeled, the plates, stiffeners, pipes and masses are individually meshed. The last step to be completed before meshing the model is to set the meshing controls, i.e. the element shape, size, the number of divisions per line, etc. Selecting the various parts of the model, one by one finite element mesh is generated. The critical portions are plates with sharp corners, curvature etc. These areas can be remeshed with advance mesh control options. "Smart element sizing" is a meshing feature that creates initial element sizes for free meshing operation. Proper care has to be taken to have the control over the number of elements and hence the number of degrees of freedom associated with the structure. This is done to have a control over the solution time. However, no compromise is made on the accuracy of the results. 2 Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd 3.3 Loading Loads are generally estimated using the classification rules or by direct hydrodynamic calculations. The loads that a ship experiences during its voyage can be roughly divided into two parts. Static Loads – These consists of loads, which do not vary with time, or even if they vary, the effect of time could be neglected. The hydrostatic pressure, Weights of the ship components, Cargo and Ballast loads come under this category. In addition to these wave moments and forces coming due to ship components are also considered as static loads. Dynamic Load – These are the loads, which vary with time, and the variation is substantially large because of which a dynamic analysis is generally required. The hydrodynamic Pressure due to waves, Wind Loads and other operational Loads like loads due to underwater Explosion, Machinery operational loads etc., are the loads, which are considered as dynamic loads. Both the above categories of loads, would act on ship and its components from time to time. Hence it becomes essential to consider the loads correctly and analyze the structure accordingly. Use of ANSYS makes the process of application of load very simple and manageable., also the chances of errors in combining the loads is eliminated. 3.4 Analysis Ones the loads are determined; different structural analyses can be carried out based on needs. The results from these analyses are extracted and checked for yielding, buckling and ultimate strength automatically at desired locations. Different Analyses that are usually performed are 1) Stress Analysis of Ship Structures and components 2) Vibration Analysis of Ship Structures 3) Ultimate Strength Analysis 4) Transient Dynamic Analysis and Strength Analysis under Impact loading 6) Thermal Analysis Before these analyses could be actually performed on the full-scale model, they are always backed up with a thorough in-house research on simpler structures like plate or plate with stiffeners etc. Suitable ANSYS models are made and appropriately loaded and boundary conditions are applied. Various analyses are then performed and the process is thoroughly checked and fine-tuned for mesh size, element type, time step (for transient dynamic and Non- Linear analysis) and other FE properties. The results of these analyses are checked with either published or experimental results. Ones these methods are established they are performed on the complex ship structures and components. This reduces the chances of errors due to wrong or un-established methods and as the FE parameters are thoroughly checked, the results are close to the actual results. Further the analysis, which are done on complex ships structures are also verified by measurements on actual ship structures. Once the results are verified, the method is finalized for subsequent analyses. Some of the analyses are briefly described below. 3.4.1 Stress Analysis of Ship Structures and components Stress analysis is usually performed to find the overall strength of the ship and its components. As there are always two or more loads acting on the structure at a time and as these loads change, based on the loading condition, hence it becomes necessary to prepare different load cases and then to analyze all or some of the load cases independently, as required. The number of load cases to be investigated depends on i) the number of envisaged cargo and ballast loading conditions and ii) number of wave cases (snapshot load sets) to be considered for each ship loading case. Sometimes it becomes necessary to carry out the structural analyses for a large number of load cases, making it absolutely essential to develop automatic processes. Thus several interfacing software programs, which connect with the FE analysis software, have been specially developed e.g. for transfer of all load data into the FE model and apply automatically. ANSYS, and the use of its macro and APDL programming helps a lot in making this process simple and error free. A simple static analysis is usually performed taking Non-Linearity (if required) into consideration. 3 Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd The results are extracted and checked for yielding, buckling and ultimate strength automatically at desired locations. Few Stress analysis projects are briefly described below 3.4.1.1 Advanced Analyses of Complex Structural Systems (Bulk carrier) Using FE Codes- The complex modeling of the complete Bulk Carrier, (Fig. 1) detailing each of its components requires advanced modeling technique and a keen technical mind. We model Bulk Carriers and other large vessels and perform direct strength Analysis with varied load cases to check the strength of the vessel. Fig 1. Bulk Carrier Model (Stress Distribution) Fig 2. VLCC Tanker Model 3.4.1.2 Optimization Of Scantlings For VLCC Tanker By Finite Element Method - On a project for unification of Ship Scantlings, a proposal of IACS working group, we had carried out calculations of scantlings, based on IRS own rules and direct structural analysis by finite element method for Panamax bulk carrier (Fig. 2) and a double hull tanker of 300000 DWT. The efficient use of FE (using ANSYS) and the results were well appreciated at international forums. 3.4.1.3 Buckling Analysis of Mini Bulk Carrier - The Static (structural stress) analysis of Mini Bulk Carrier (Fig 3) was carried out to check the strength adequacy due to local (Hydro static and hydro dynamic pressure and cargo load) and global loads (Still water bending moment and wave bending moment). For this various pressures, Forces and Moments were all applied simultaneously for the analysis. The hatch coaming area has been specially investigated for buckling for various axial loads. The complete project was done in a record time, which would have not been possible without the use of advanced FE software, ANSYS. Fig 3. Mini Bulk Carrier (Stress Distribution) Fig 4. FE Model of Fast patrol Vessel 4 Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd 3.4.1.4 Static And Dynamic Analyses Of Fast Patrol Vessel - A static and free vibration analysis of the vessel was done to simulate the loads resulting from lightweight, high speed and slamming pressure. The vessel, made up of steel and aluminum (Fig 4), has to be checked against the water jets and slamming loads. The static analysis was carried out under these loading conditions. The free vibration analysis of the entire vessel and superstructure were performed to estimate the natural frequency and the mode shapes for avoiding resonance with other machinery components. 3.4.1.5 Transverse Strength Analysis of LSTL Hull Structure - The transverse strength analysis is done to simulate the loads due to oblique wave, rolling of the ship and unsymmetrical cargo loading. The transverse strength computations of the Landing Ship Tank (Large) [LST (L)], (Fig 5) has been examined for following loading conditions: a) Lightship b) Transport role ‘A’ & ‘B’ vehicles – Departure c) Transport role ‘A’ & ‘B’ vehicles – Arrival d) Beaching role ‘A’ & ‘B’ vehicles – Arrival e) Replenishment role – Departure f) Replenishment role – Arrival. The FE results helped, the shipyard, a lot to modify the design to withstand these loads. Fig 5. FE Model of LST (L) -Stress Distribution Fig 6. Effect of Torsional Loads on Acid Carrier 3.4.1.6 Effect Of Torsional Loads On An Acid Carrier Of Wide Hatch Opening - Torsional analysis is important for vessels with wide hatch openings and single bottom structure (Fig 6). The main objective of this study was to develop a method to improve the structural adequacy with respect to warping displacement and stresses, by 3-D finite element method. The analysis was carried out using ANSYS, for cargo loading, dynamic forces and hydrodynamic torque due to oblique wave with appropriate boundary conditions. The results were verified with the one, available in literature and were found satisfactorily matching. Hence suitable modifications were suggested to the client. 3.4.1.7 Flexure analysis of Advanced Offshore Patrol Vessel - The objective of this project was to determine the axial stress on longitudinal member as well as on super structure due to total hull girder bending moment. Full ship (Fig 7) has been modeled from frame no.32 to frame no.140 so that whole superstructure is covered. Total bending moment was applied on both ends of model. The results showed that the axial stress on one of the deck was more than the critical buckling strength. Hence, modifications were suggested to the client. Fig 7. Deflected Shape of AOPV Fig 8. Ship at Campus 5 Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd 3.4.1.8 Ship at Campus - The Ship at Campus, designed to be used to train Seafarer in general and engineering training in particular. This 23 m long (950 tones DWT), half ship (Fig 8) will be erected on a concrete foundation. The main engine will be kept at a separate concrete foundation to avoid transmission of vibrations to the main hull. ANSYS was used to help the client to design the scantlings of both ship and the foundation. Finite Element analysis, using ANSYS, was carried out to calculate the loads on the foundation and strengthen the moon-pool area. The scantlings were optimized by detailed analysis to safely transmit the required dead weight and lightweight into foundations. 3.4.1.9 3-D static analysis of cold water box for OTEC barge - This structure is connected to the deck of the barge of an Ocean Thermal Energy Conversion plant, (Fig 9) which generates electricity from the seawater temperature gradient. The cold water pipes are attached with this structure from 2 km depth of seabed. The self-weight of the box, hydrostatic, hydrodynamic (wave ¤t), buoyancy and pipe weight were considered as the applied loads. The static analysis was carried out using a simplified model to find out the strength adequacy of the structure under the applied loads. Fig 9. Cold Water Box on Barge Fig 10. Gun Support Structure 3.4.1.10 Gun Support Structures - The natural frequencies and stresses for stated recoil loads and loads due to wind, ship motions etc were analyzed using ANSYS for the Gun Support Structure (Fig 10) of a vessel for a foreign agency. Different loading cases were analyzed to ensure the adequacy of the structure in all possible load combinations. Modifications were suggested based on thorough study of the results. 3.4.1.11 Design Analysis of Forward part of Hull Structure for Air Defense Ship - The shell structure forward of FR 16 of ADS (Fig 11) has been analyzed to study adequacy of structural strength against Bottom Slamming pressure and Bow flare impact pressure. The slamming and bow flare pressure was calculated as per IRS and LRS Naval rules. The detailed finite element analysis has been done for various models at different locations. Thorough In-house research was done before finalizing the method for analysis of such a real time condition. Fig 11. Forward Part of hull Structure (ADS) Fig 12. Stress Distribution on Skeg 6 Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd 3.4.1.12 Design Analysis of Skeg Structure - A detail 3-dimensional FE analysis of the skeg structure (Fig 12) of Air Defense Ship has been carried out to check the structural adequacy of the proposed design for two different loading conditions. Static Analysis (Linear) of skeg structure has been done to find out the maximum deflections and combined stresses after docked condition. While non-linear analysis, has been carried out to check for buckling in the process of docking of the ship. 3.4.1.13 Mast Static and Dynamic analysis for various vessels - The strength of the mast structure (Fig 13) was estimated due to the wind and ship motion loads. This mast accommodates radar antenna bases and for the proper functioning of the equipment, the deflection of the mast for operating frequencies of the radar should be limited, hence a transient dynamic analysis was also done to determine the deflection due to the ship motion. The structure was modified to restrict the deflection and resulting stresses within allowable limit. The adequacy of the mast structure subjected to wind load and ship motion load are checked on the modified structure and the stresses are kept within allowable limit. Fig 13. Deflection of Mast Fig 14. Deflection Plot of Helideck 3.4.1.14 Structural Analysis Of Heli-Deck Of Advanced Offshore Patrol Vessel - The main objective of the structural analysis of Heli-Deck for Advanced Offshore Patrol Vessel (Fig 14) was to determine the strength of heli-deck for normal landing and emergency crash landing of the helicopter. The analysis was also carried out based on NES154 standards. The elasto-plastic analysis was carried out, using ANSYS, based on allowable permanent deflection criteria. 3.4.1.15 Ship Lift System - The Ship Lift System, shown in Fig 15, is used to transport the naval vessel from the sea to the repair shed. These whole systems have upward, longitudinal and transverse movement during the full operation. The transverse movement at a junction was found to have problems during shifting from longitudinal movement at the rail and crossing piece. Hence, a FE analysis was done to analyze and re- design the transfer system so that it could effectively transfer the ship from sea to desired repair location. The recommendation suggested was rectified in the system and tested successfully. Fig 15. Ship Lift System 7 Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd 3.4.2 Vibration Analysis of Ship Structures With the progress made in the field of FE analysis and methods developed to cut down time, it is now possible to use FE analysis to predict vibration characteristics of ship. It is desirable to perform a Free vibration analysis during design stage of a vessel to estimate the natural frequencies in various mode shapes, as any changes later are difficult, if not impossible. This analysis is normally carried out for important and representative ship loading conditions e.g. Light Ship, Fully loaded departure/arrival and Ballast departure/arrival conditions, which cover the major variation of loading during voyage. Added mass is suitably incorporated to simulate the vibration of elements in contact with water. In respect of the global i.e. hull girder vibration modes; it is customary to investigate the 1,2,3 and 4 noded vertical, horizontal, torsional modes and the respective natural frequencies of vibration. These are compared with the major excitation frequencies e.g. propeller blade frequency, engine/ shaft frequency, main generators frequency etc. to avoid resonance. Similarly it is useful to model local structures for e.g. engine room, funnel and the super structure/deck houses to avoid potential area of resonance. Necessary corrective action can be taken at the design stage by rearrangement of structural elements and/or by increasing the scantlings. The forced vibration analysis wherein the time varying forces from machinery (propeller, engine etc.) are also taken into account can provide useful information such as the displacement, velocity and acceleration at critical locations. These responses can be compared to ensure compliance with acceptable standards. Few important vibration analysis projects are briefly described below 3.4.2.1 Determination of natural frequencies of a cement carrier - During the sea trail of this cement carrier, shown in Fig 16, excessive vibration was sensed and also measured by our surveyor. In view of that, finite element analysis of superstructure, including engine room and steering gear compartment was carried out to find out the natural frequencies and mode shapes. From the analysis result, excessive vibration was found at the same locations, which the surveyors had detected during the trial. The remedial measures to reduce excessive vibration were identified and made. After the modification the vibration and noise level came down to the acceptable limits Fig 16. Mode Shape of Cement Carrier Fig 17. Mode Shape of 500 Passenger Vessel 3.4.2.2 Vibration Analysis of 500 Passenger Vessel - Vibration analysis for a passenger vessel designed for well-known Indian Shipyard, Fig 17, was carried out to estimate the natural frequencies of the first 40 modes of vibration in various loading conditions. A 3D shell-beam model of the complete ship in all details was created using the pre-processor of ANSYS 8.0. The vertical, horizontal and torsional modes of hull girder frequencies for various loading conditions were compared with the frequencies of engine, shaft and propeller. Suitable recommendations were made to avoid resonance. 3.4.2.3 Vibration Analysis of OPV’s, FAC’s and AOPV’s - Vibration Analysis of Naval Vessels is of prime importance due to the kind of conditions and the type of service they operate on. We model the entire vessel, shown in Fig 18, carefully and perform Vibration analysis to find the natural frequency 8 Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd of the same and also to check if forcing frequency matches with the natural frequency to create resonance. Suitable modifications, if any, are then recommended to the yard. Fig 18. Mode Shape of a Naval Vessel Fig 19. Mode Shape of a Mast 3.4.2.4 Vibration Analysis of Masts fitted in Various Vessels- Masts fitted on ships carry important navigation and communication components, which are very sensitive to vibrations. And, it is constantly acted upon by wind and acceleration loads. Hence it becomes very important to check the vibration and strength of masts for the specified operation. The mast is modeled in complete detail and free vibration analysis is performed, Fig 19, fitted to check if it could operate safely with the level of vibrations, which arise due to the running of the main engine, Pumps etc. Modifications if any, are suggested to the client. 3.4.3 Ultimate Strength Analysis Collapse of hull girder is an important failure mechanism for ships as it can cause huge losses of life & property and marine pollution, particularly in case of large ships. Therefore it becomes essential to check the ultimate hull girder strength against the combined vertical wave bending moments and still water bending moments, including those in the flooded conditions. The ultimate hull girder strength against bending can be calculated using either the simplified methods such as that based on incremental-iterative approach or by nonlinear FE analysis. In the incremental-iterative approach the stress-strain relationship for all stiffened plate elements are established separately for when under tension and when under compression. Finite Element Method, which not only takes into consideration complex geometries associated due to initial imperfections but also the geometrical non-linearity and the material non-linearity. It is possible to include the effects of internal loads due to ballast water and cargo. The midship section is modeled including all longitudinal members between web frames and moments are applied incrementally on the model end. The analysis results in the curvature vs the ultimate moment carrying capacity curve to provide the ultimate hull girder bending moment capacity 3.4.3.1 Ultimate Strength of Tankers, bulk Carriers and Container Ships - The aim of this project was to develop a procedure to determine the ultimate strength of the hull girder of ships considering all possible modes of progressive failure. The work was carried out as a part of combined research conducted by the Asian Class Societies. All longitudinal strength members between two web frames were modeled in detail for the full transverse sections, using shell elements and fine mesh. Static non- linear elasto-plastic analysis was carried out considering the global vertical bending moments (Sagging and Hogging) and horizontal bending moments applied at the ends of the structure. The Ultimate collapse moment was determined for different ships and was compared with Rule allowable bending moments to provide an indication of the reserve bending strength at the very extreme loads. 9 Analysis of ship structures using ANSYS SeaTech Solutions International (S) Pte Ltd 35000 30000 25000 m) m 20000 Base ( m 15000 n fro 10000 ocatio L 5000 0 -350 -250 -150 -50 50 150 250 350 Compression Axial Stress (Mpa) Tension Fig 20. Stress Distribution (Mid-Ship Section) Fig 21. Variation of Axial Stress along Depth of Ship 3.4.3.2 Determination of ultimate collapse pressure of hatch cover - In certain cases of bulk carrier total losses, failure of the foreside hatch covers due to abnormal waves has been sited as initial cause leading to flooding and subsequent loss. In this project a method was developed, for determining the ultimate strength of hatch covers by non-linear FEM. The load is increased in step increments and both the region of material plasticity and deflection are monitored. The practical ultimate strength is determined up to a point when the hatch cover fails to perform its assigned function of keeping sea outside of the ship. Fig 22. Stress Plot of Hatch Cover 3.4.4 Transient Dynamic and Strength Analyses under Impact Loading The wave loads discussed above are dynamic in the sense that they are time varying, the frequency of the cyclic variation being similar to the frequency of encountering waves. This being comparatively low, it is possible to consider them as quasi-static loads and add to the still water loads. However there are other types of highly dynamic loads, which are characterized by very high amplitude but short durations usually lasting up to few milli-seconds e.g. slamming loads, under water shocks, contact/ collision etc. To fully understand the effects of such loads the use of a non-linear transient dynamic analysis is necessary. Nonlinear transient dynamic analysis is carried out in time domain, wherein the loads are varied at each time step. Material and geometrical non-linearities are accounted, thus it is possible to investigate post- elastic stage and estimate any permanent deformation left after the load history. This kind of analysis usually requires extensive research due to the extreme sensitivity of the results on the Finite Element Parameters. 3.4.4.1 Analysis of FSP subjected to Underwater Explosion - Now a day, all naval vessels in addition to analysis to Normal Operational Loads, needs to checked for Explosive loads as well. We have already started developing methods to study this complex phenomenon of structures subjected to Explosive Loads. In a preliminary study we have analyzed a Floating Shock Platform (Fig 23) under shock loads. The results matched closely with a similar study made by a Naval Department. 10
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