While designing jet-engine components information about the loads that the component will be subjected to, is critical. For this, a full system analysis of the engine is often performed with every component put together in a large finite element model, which is called the whole engine model (WEM). This model will mostly be composed of lower order shell elements with a few thousands of elements. At the design level of a component, the FE model is detailed with several hundred thousand higher order solid elements. The detailed model cannot be directly put into the whole engine model due to excessive run times. Therefore there must be a simpler representation of the component -a sub-model- with much fewer elements so that it can be assembled into the whole engine model. This simple model must have the same stiffness (load/displacement) in chosen directions, the same mass and the basic mode shapes and frequencies should also be the same with the detailed model. 4 different structural optimisation schemes were studied to prepare a model: sizing optimisation, optimisation with material properties as design variables, combined sizing and material property optimisation and free-size optimisation. Among these free-size optimisation where each element in the model has its own design variable -thickness- was found to be the most effective method. The stiffness could be matched to the detailed model as close as 5% and so also could the first two fundamental mode shapes and frequencies. Additionally, the initial sub-model prepared was used to do a preliminary study on how variations in casting dimensions would affect the stiffness of the component in a certain direction. This was done by creating a design of experiments (DoE) for the stiffness. A response surface for the stiffness was created in terms of the dimensions that have the most significant effect. This was later used to predict an interval for the stiffness based on variations in the cast dimensions with a confidence level of 99.7%.

Afin de répondre aux besoins du marché de l’acier, le procédé de cokéfaction du charbon doit s’adapter. Cependant, changer les paramètres de cokéfaction du charbon, tels que la température du four, le temps de cuisson ou la composition de la pâte à coke enfournée, peut générer un endommagement prématuré de la maçonnerie des fours. En effet, la transformation du charbon en coke s’accompagne d’une poussée sur les parois du four fortement dépendantes d’un grand nombre de paramètres. Afin d’anticiper ce problème, un projet européen nommé « Swelling PRessure In a coke oven, Transmission on oven walls and COnsequences on wall » a été mis en place. Cette thèse s’inscrit dans ce programme et vise à déterminer la poussée maximale pouvant être admise par un piédroit de cokerie lors de la pyrolyse du charbon. Pour modéliser ces structures composées de plusieurs centaines de milliers de briques, le point de vue macroscopique est le plus approprié. La maçonnerie est remplacée par un matériau homogène équivalent dont le comportement varie en fonction de l’état d’endommagement de la maçonnerie, ramené localement à un état d’ouverture des joints de mortier. Afin de détecter ces ouvertures, un critère de type Mohr-Coulomb en contraintes est utilisé. Il repose sur la comparaison des limites à rupture d’un sandwich brique-Mortier déterminé expérimentalement à haute température avec les contraintes mésoscopiques issues de la simulation. Un protocole expérimental novateur a été développé pour caractériser la tenue en traction du sandwich brique / mortier / brique jusqu’à 1000°C. Les limites à rupture issues de cet essai de traction directe ont été comparées à celles obtenues par des essais de fendage réalisés à l’université de Leoben. Les résultats sont concordants et confirment l’importance de l’état de surface avant maçonnage. Selon l’état d’endommagement considéré, les contraintes mésoscopiques sont obtenues grâce à un tenseur de localisation ou grâce à une sous-Structuration. Cette étape de sous-Structuration consiste à simuler localement une cellule à l’échelle mésoscopique en lui appliquant le champ de déplacement macroscopique obtenu grâce à la simulation. L’outil numérique a été validé par confrontation avec un cas test de référence. Pour finir, l’outil numérique développé a été utilisé pour caractériser l’influence de différents paramètres tels que la prise en compte de la thermique, la mise en compression de la structure…. Enfin, la simulation de cuissons sur des piédroits complets (sains ou initialement endommagés) a été réalisée. L’importance de l’endommagement initial est clairement soulignée par les résultats. Enfin, un nouveau modèle, appelé « deux carneaux avec poutres», est proposé pour réduire le coût de calcul. Plus complet que le modèle « deux carneaux » utilisé au CPM, il donne accès à de très bons résultats pour un coût nettement moindre que celui du piédroit complet avec homogénéisation et sous-Structuration. / To face coke and steel market requirements, the coking process has to be more flexible. Changing process parameters such as coking temperature, blend composition and cooking time can damaged coke oven battery heating wall. Indeed, the coking process generates a swelling pressure on wall which depends on a lot of parameters. To study this point, a European project named « Swelling PRessure In a coke oven, Transmission on oven walls and COnsequences on wall » has been set up. This work is a part of it and aims to determine the admissible pushing pressure for the coke oven heating walls to prevent crack formation. To model large masonries composed of numerous bricks, a mesoscopic point of view is more appropriate. Bricks and mortar are replaced by a Homogeneous Equivalent Material (HEM) whose behaviour depends on the joint state. In order to represent joint opening mechanism, a Mohr-Coulomb criterion in stress is used. This criterion compares the level of stress to the ultimate tensile or shear stress at mesoscopic scale. Ultimate stresses are obtained thanks to an experimental campaign using a new protocol developed at PRISME Laboratory. The brick-Mortar behaviour is experimentally characterised at high temperature (20°C to 1000°C). To validate the tensile test developed, a second experimental campaign using “wedge splitting tests” has been done at Leoben University. Results are similar and confirm the importance of the brick surface state. Depending on the initial damage of the structures, mesoscopic stresses are obtained by localization tensor or by sub-Modelling. The sub-Modelling step aims to simulate a local part of the masonry at the mesoscopic scale. This step aims to simulate with a mesoscopic point of view a local part of the global model. This numerical tool has been validated thanks to a literature test. Finally, the numerical tool has been used to characterise the influence of some parameters (thermal, force due to the cross tie rod,..). Next, the simulation of the whole coke oven heating wall has been performed (undamaged or initially damaged masonry). These FE simulations show the influence of initial damage on the final masonry damage. Finally, a two flues model with beams is proposed to take into account compression due to cross tie rod and to limit computational cost. It permits to obtain better results than the existing two flues model used at CPM with a lower cost compared to the whole coke oven heating wall model.

This thesis work is carried out in Cargotec Sweden AB, Bromma Conquip to study the behavior of load carrying welded joints in different weld metal strength mismatch conditions and various penetration ratios. Static and fatigue strength calculations have been made using FEA and experimentation. The joint in the Telescopic beam of the spreader STS45 has been analyzed. Telescopic beam is one of the critical and main parts in the spreader, which is directly subjected to the load of containers at various ports. Previous studies show that this joint limits the strength of the spreader, it has thus been analyzed. To check the effect of different strength mismatch conditions in the weld metal, static strength calculations have been carried out. The effect of different penetration ratios on static and fatigue strength has also been studied. A cruciform test specimen is designed according to the joint configuration and the capacity of testing machine. Criteria for the selection of consumables has also been developed and following standards: Eurocode 3, AWS D1.1 and BSK07, have been compared for static joint design. Sub modelling, effective notch stress and beam theory techniques have been used to study the effect of weld metal penetration and size of weld throat on the fatigue strength of the welded joint in the Telescopic beam. The study show that matching or slight under matching in the filler material along with full penetration increases the ultimate strength capacity as well as the ductility in the joint. Results of Eurocode 3, AWS D1.1 and BSK 07 are close to each other. Apart from strength mismatch and penetration ratios, it is observed that the weld geometry and joint preparation has also effect on the strength of the joint. Fatigue analysis of the weld in the Telescopic beam using 3D Finite element analysis show that effective notch concept is not applicable to this part of the spreader.