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Ship Construction and Welding PDF

322 Pages·2017·8.9 MB·English
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Springer Series on Naval Architecture, Marine Engineering, Shipbuilding and Shipping 2 Nisith R. Mandal Ship Construction and Welding Springer Series on Naval Architecture, Marine Engineering, Shipbuilding and Shipping Volume 2 Series editor Nikolas I. Xiros, University of New Orleans, New Orleans, LA, USA TheNavalArchitecture,MarineEngineering,ShipbuildingandShipping(NAMESS) series publishes state-of-art research and applications in the fields of design, construction,maintenanceandoperationofmarinevesselsandstructures.Theseries publishesmonographs,editedbooks,aswellasselectedPh.D.thesesandconference proceedings focusing on all theoretical and technical aspects of naval architecture (includingnavalhydrodynamics,shipdesign,shipbuilding,shipyards,traditionaland non-motorized vessels), marine engineering (including ship propulsion, electric power shipboard, ancillary machinery, marine engines and gas turbines, control systems,unmannedsurfaceandunderwatermarinevehicles)andshipping(including transportlogistics,route-planningaswellaslegislativeandeconomicalaspects). More information about this series at http://www.springer.com/series/10523 Nisith R. Mandal Ship Construction and Welding 123 Nisith R. Mandal DepartmentofOceanEngineeringandNaval Architecture Indian Institute of Technology Kharagpur Kharagpur, West Bengal India ISSN 2194-8445 ISSN 2194-8453 (electronic) SpringerSeries onNaval Architecture, Marine Engineering, ShipbuildingandShipping ISBN978-981-10-2953-0 ISBN978-981-10-2955-4 (eBook) DOI 10.1007/978-981-10-2955-4 LibraryofCongressControlNumber:2016956183 ©SpringerNatureSingaporePteLtd.2017 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfrom therelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinor foranyerrorsoromissionsthatmayhavebeenmade. Printedonacid-freepaper ThisSpringerimprintispublishedbySpringerNature TheregisteredcompanyisSpringerNatureSingaporePteLtd. Theregisteredcompanyaddressis:152BeachRoad,#22-06/08GatewayEast,Singapore189721,Singapore Preface Thisbookaimstointroducevariousaspectsofshipconstructionstartingfromship types,material ofconstruction, welding technology to accuracy control.This book is the outcome of my experience of teaching Ship Construction and Welding Technology, Design and Construction of Ocean Structures, Marine Construction and Repair Techniques as regular and elective courses in undergraduate and graduate curricula during about past 30 years in the Department of Ocean EngineeringandNavalArchitectureatIITKharagpur.Whileteachingandworking in this field, I felt the lack of a suitable book covering the various basic aspects of ship types, its structural components, materials, and aspects of its welding and dimensional control. This inspired me to get on this job and provide the budding navalarchitectswithacomprehensivebookonshipconstructionandwelding.The contents of the book have been logically organized and spread over 21 chapters. Itstartswithintroducingtothenovicereaderthevarioustypesofshipsbasedon cargo type and functionality and also the basic characteristics of shipbuilding industry. It then goes on to describe the various loads experienced by the ship structure and thereby working out suitable structural arrangement to sustain these loads.Thisformsthebackgroundtotheintroductionofthetypesofframingsystem, basic structural components, structural subassemblies and assemblies. All of these are explained with necessary illustrations and details. The book then goes on to work out the midship sections of some of the most widely used ship types, explaining the design strategy based on functionality. The book also includes the aspectsofstructuralcompensationforunavoidablediscontinuitiesinshipstructure. Next the book covers various aspects of material of construction. It includes material description, classification requirements and different methods of steel material preparation. Subsequently different methods of metal cutting, plate and sectionformingareintroducedalongwiththeconceptoflineheatingforobtaining compound curvature plates. The reader is then introduced to various welding techniques related to ship- building industry. Here different fusion welding methods, power sources, effect of welding process parameters, metal transfer mechanism are discussed in detail. The solid-state welding technique suitable for aluminum welding has also been v vi Preface incorporated. The formation of weld-induced residual stresses and distortion has alsobeenexplainedindetail.Itthengoesontopresentin-processdistortioncontrol andmitigationtechniquessuchasheatsinking,thermo-mechanicaltensioning,etc. suitable for ship structural units. Finally, the book introduces various possible weldingdefectsthatoneislikelytoencounterinweldedstructuresandexplainsthe nondestructive testing methods those are relevant to ship construction. With all the construction done, it is necessary to have a suitable mechanism to knowtherangesofvariationsinstructuralfabricationsothatonecanquantitatively target the end product accuracy. To address this aspect a chapter on accuracy control has been included in this book. I believe the contents of this book should prove useful to the students of naval architecture and ocean engineering as well as the shipbuilding professionals. Kharagpur, India Nisith R. Mandal July 2016 Acknowledgement The author with all humility wishes to acknowledge the encouragement he got through teaching Marine Construction and Welding to several batches of B.Tech. students over these years in the Department of Ocean Engineering and Naval Architecture at IIT Kharagpur. He would like to specially acknowledge the help provided by some of his research scholars and graduate students, namely Ms. Malabika Adak, Sri Pankaj Biswas, Sri Debabrata Podder, Sri Amith Gadagi, Sri Anudeep Joshi, Sri K.S. Kapaleeswaran, Sri Chandra Shekhar, Sri Sanyappa Pujari, Sri Chandra Shekhar, SriP.MohanRaviKumar,SriAbhayKumar,SriSharatKumar,aScientificstaffin the Marine Construction and Welding Lab and Sri Atanu Pal, Technical Superintendent in working out various examples and conducting experiments involving various aspects of welding and welding distortion. The author would like to put on record the encouragement and active support he got from Sw. Suddhidanandaji Maharaj of Advaita Ashrama, Kolkata, Prof. Hidekazu Murakawa and Prof. Ninshu Ma of Joining and Welding Research Institute, Osaka University, Prof. Purnendu Das of Strathclyde and Glasgow University and Prof. Sreekanta Das of Windsor University, Canada. The list is definitely not exhaustive, there are many who directly and indirectly provided support and guidance in compilation of this work. The author is also very much grateful to the staff of Marine Construction and Welding Laboratory, Sri Brotin Dey, Sri Biplab Das, Sri Subhas Josef, Sri Bharat Karar and Ms. Salma for all the long hours they devoted spontaneously even after working hours in carrying out tedious welding experiments. The author is indeed very much thankful to the Chairman and Managing DirectorofCochinShipyardLtd.forkindlypartneringwithustoconductfull-scale distortion control and accuracy control experiments on live projects. Thanks are especiallyduetoSriS.Harikrishnan,SriThomasMathew,SriP.J.Vargheseandall the workers involved in the work at Cochin Shipyard Ltd. The help extended to the author in conducting various studies relating to ship- yard production and welding by Mazagon Dock Ltd., Mumbai and Garden Reach vii viii Acknowledgement ShipbuildersandEngineersLtd.,Kolkataisdulyacknowledged.Thesestudieshave greatly contributed to the text content of this book. The author wishes to sincerely acknowledge the word processing and drafting supportofMs.ShreyaMallick.Finally,theauthoracknowledgeswithgratitudethe support of Continuing Education Cell of IIT Kharagpur in preparation of this manuscript. Without the sanction of Divine Will not even a blade of grass moves in this world. The entire work that has been done became possible only because of HIS wish and HIS mercy. Nisith R. Mandal Contents 1 Introduction to Ships ... ..... .... .... .... .... .... ..... .... 1 1.1 Ship Types .. .... ..... .... .... .... .... .... ..... .... 2 1.2 Basic Features.... ..... .... .... .... .... .... ..... .... 3 References. .... .... .... ..... .... .... .... .... .... ..... .... 19 2 Characteristics of Shipbuilding Industry. .... .... .... ..... .... 21 3 Structural Requirement . ..... .... .... .... .... .... ..... .... 25 3.1 Longitudinal Strength... .... .... .... .... .... ..... .... 27 3.2 Transverse Strength..... .... .... .... .... .... ..... .... 29 3.3 Torsional Strength. ..... .... .... .... .... .... ..... .... 29 3.4 Local Strength ... ..... .... .... .... .... .... ..... .... 30 3.5 Structural Arrangement.. .... .... .... .... .... ..... .... 30 3.6 Framing System .. ..... .... .... .... .... .... ..... .... 33 3.6.1 Longitudinal Framing System . .... .... ..... .... 33 3.6.2 Transverse Framing System... .... .... ..... .... 36 4 Basic Structural Components.. .... .... .... .... .... ..... .... 39 4.1 Longitudinal and Transverse Members.. .... .... ..... .... 39 4.2 Girders and Transverses . .... .... .... .... .... ..... .... 40 4.2.1 Centre Girder.. .... .... .... .... .... ..... .... 41 4.2.2 Side Girder ... .... .... .... .... .... ..... .... 41 4.2.3 Hatch Side Girder .. .... .... .... .... ..... .... 42 4.2.4 Hatch End Beam... .... .... .... .... ..... .... 42 4.2.5 Deck Transverse ... .... .... .... .... ..... .... 42 4.3 Stringers.... .... ..... .... .... .... .... .... ..... .... 44 4.4 Floors.. .... .... ..... .... .... .... .... .... ..... .... 44 4.4.1 Plate Floor.... .... .... .... .... .... ..... .... 45 4.4.2 Bracket Floor.. .... .... .... .... .... ..... .... 45 4.4.3 Water Tight Floor .. .... .... .... .... ..... .... 46 4.5 Brackets .... .... ..... .... .... .... .... .... ..... .... 46 References. .... .... .... ..... .... .... .... .... .... ..... .... 48 ix

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This book addresses various aspects of ship construction, from ship types and construction materials, to welding technologies and accuracy control. The contents of the book are logically organized and divided into twenty-one chapters.The book covers structural arrangement with longitudinal and trans
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