My Master Thesis Presentation - Application of Line Heating Method in Shipbuilding Industry. Submitted: April 2009.

1. Alexandria University
Faculty of Engineering
Application of Line Heating Method
In Shipbuilding Industry
1
“‫السفن‬ ‫بناء‬ ‫صناعة‬ ‫فى‬ ‫الخطى‬ ‫التسخين‬ ‫طريقة‬ ‫تطبيق‬”
9-Apri-2009
Submitted by
Engr. Kamal Hassan Kamal Mohamed
Supervisors
Prof. Dr. Ahmed El-Badan
Prof. Dr. Ahmed Mohamed Rashwan
Naval Architecture & Marine Engineering Department
Faculty of Engineering
Alexandria University
Submitted: April 2009

2. THESIS OUTLINES
1. INTRODUCTION
2
2. AIM OF THE STUDY
3. THE PRINCIPLES OF HEATING OF METALS
4. PARAMETERS AFFECTING PERMANENT DEFORMATIONS
5. LINE HEATING FORMING PROCEDURES
6. EXPERIMENTS VERIFICATION
7. CONCLUSION
8. RECOMMENDATIONS FOR FUTURE WORK
9-Apri-2009

3. 1. INTRODUCTION
1. Quicker and more accurate
than methods using heavy
machinery.
2. Build much more complicated
shapes with only minor
investment in new equipment.
3
Line Heating Advantages:Line Heating
Press
Roller
9-Apri-2009

4. 2. AIM OF THE STUDY
To build a scientific practical guide in
forming flat plates to certain shapes
by Line Heating Method.
49-Apri-2009

5. 3. THE PRINCIPLES OF HEATING OF METALS
 Phenomenon of Heating of Metals
Fig. 3.2: Schematic diagram showing
basics of creating permanent deformation
from heating
Fig. 3.1: Schematic representation of permanent
deformation due to single heating line.
The compressive plastic strain is the main source for the body
permanent deformation and residual stresses.
59-Apri-2009

6. These simple examples suggest the following:
1. The shrinkage is important to form a spherical shape which has
curvatures in two directions.
2. The bending angle is necessary to create cylindrical shape which has
unidirectional curvature.
 Line Heating Idea
Fig. 3.3: Forming of cylinder shape Fig. 3.4: Forming of shallow spherical shell shape
69-Apri-2009

7. 4. PARAMETERS AFFECTING PERMANENT
DEFORMATIONS
 Maximum Heating Surface Temperature
79-Apri-2009

8. Fig. 4.1: Bending angle as a function of heat input power [10]
8
 Effective Heat Input Power
9-Apri-2009

9.  Plate Thickness and Heating Torch Travel Speed
 Torch Tip-Plate Separation
Fig. 4.2: Torch tip-plate separation detail
99-Apri-2009

10. Fig. 4.3: Bending angle obtained with no
initial stress (0 N/mm2) [4]
Fig. 4.4: Bending angle obtained with
initial stress (-80 N/mm2) [4]
Fig. 4.5: Bending angle obtained with
initial stress (-160 N/mm2) [4]
 Initial Stress
109-Apri-2009

11.  Cooling Method
Fig. 4.6: Cooling on the heated side of steel plate.
Fig. 4.7: Cooling on the back side
of steel plate
119-Apri-2009

12. 5. LINE HEATING FORMING PROCEDURES
Fig. 5.1: Usual Different Forms of Curved Plates in Ship Structure
129-Apri-2009

13. a) Single Curvature Shape
 Constant Curvature Shape in Transverse Direction without Twist
Fig. 5.2: Constant Curvature Shape in the
Transverse Direction without Twist
Fig. 5.3: Heating Application Sequence
Constant Curvature Shape in the Transverse
Direction without Twist
139-Apri-2009

14.  Constant Curvature Shape in Transverse Direction with Twist
Fig. 5.4: Constant curvature shape in
the transverse direction with twist
Fig. 5.5: Heating application sequence
for constant curvature shape in the
transverse direction with twist
149-Apri-2009

15.  Variable Curvature Shape in Transverse Direction
Fig. 5.6: Variable curvature shape in the transverse direction
159-Apri-2009

16. b) Double Curvature Shape in the Same Direction of the
Plate Surface – Longitudinal Concave Curvature Shape
(Pillow Shape)
Fig. 5.27: Longitudinal concave
curvature shape (Pillow Shape)
169-Apri-2009

17.  Longitudinal Concave Curvature Shape without Twist
Stage 1 Stage 2
 
 22
22
2
Tradrad
T
Trad
T
rad
hy
hW
NOHL
hy
hW
NOHL
R
W
NOHL











 
22
22
481.0
4
481.0
4
LTT
TL
LT
TL
hL
hhL
NOHT
hL
hhL
NOHT








(Eq. 4.1)
(Eq. 4.3)
Fig. 5.8: Heating application sequence for longitudinal concave
curvature without twist 179-Apri-2009

18.  Longitudinal Concave Curvature Shape with Twist
Stage 1 Stage 2
 
 22
1
22
1
1
2
Tradrad
T
Trad
T
rad
hy
hW
NOHL
hy
hW
NOHL
R
W
NOHL











 
22
22
481.0
4
481.0
4
LTT
TL
LT
TL
hL
hhL
NOHT
hL
hhL
NOHT








(Eq. 4.2) (Eq. 4.3)
Fig. 5.9: Heating Application Sequence for longitudinal
concave curvature with twist 189-Apri-2009

19. c) Reverse Double Curvature Shape – Longitudinal convex
curvature Shape (Saddle Shape)
Fig. 5.10: Longitudinal convex curvature shape
Fig. 5.11: Line heating technique details for forming the longitudinal convex curvature shape (Saddle shape)
199-Apri-2009

20.  Longitudinal Convex Curvature Shape without Twist
Stage 1
 
22
22
481.0
4
481.0
4
LLL
TL
LL
TL
hL
hhL
NOHL
hL
hhL
NOHL








(Eq. 4.1) (Eq. 4.4) 
 22
22
2
Tradrad
T
Trad
T
rad
hy
hW
NOHL
hy
hW
NOHL
R
W
NOHL











Stage 2
Fig. 5.12: Heating sequence for longitudinal convex curvature shape without twist
209-Apri-2009

21.  Longitudinal Convex Curvature Shape with Twist
Stage 1
 
 22
1
22
1
1
2
Tradrad
T
Trad
T
rad
hy
hW
NOHL
hy
hW
NOHL
R
W
NOHL











 
22
22
481.0
4
481.0
4
LLL
TL
LL
TL
hL
hhL
NOHL
hL
hhL
NOHL








Stage 2
(Eq. 4.2)
(Eq. 4.4)
Fig. 5.13: Heating sequence for longitudinal convex
curvature shape with twist 219-Apri-2009

22. d) Double Curvature Shape due to Twist on the Plate Surface
Fig. 5.14: Twisted Curvature Shape
Fig. 5.15: Heating sequence for twisted curvature shape
229-Apri-2009

23.  Line Heating Tools
 Line Heating Workstation
23
6. EXPERIMENTS VERIFICATION
9-Apri-2009

24. 24
 Modals Dimensions & Line Heating Conditions
9-Apri-2009

25. 259-Apri-2009

26. 26
 Experiments of Single Curvature Shape
1. Constant Curvature Shape in Transverse Direction without Twist
(Expr.1) Plate Dims. 12X4060X1789 mm.
9-Apri-2009

27. Fig. 6.1: The result of Experiment No. 1
279-Apri-2009

28. 28
2. Constant Curvature Shape in Transverse Direction with Twist
(Expr.2) Plate Dims. 12X1500X900 mm.
9-Apri-2009

29. Fig. 6.2: The result of Experiment No. 2
299-Apri-2009

30. 30
3. Variable Curvature Shape in Transverse Direction (Expr.3) Plate Dims.
10X3000X(820+720) mm.
9-Apri-2009

31. Fig. 6.3: The result of Experiment No. 3 Part (1) 319-Apri-2009

32. Fig. 6.4: The result of Experiment No. 3 Part (2)
329-Apri-2009

33. 33
1. Longitudinal Concave Curvature Shape without Twist (Expr.4)
Plate Dims. 10X1500X900 mm.
 Experiments of Double Curvature Shape in the Same
Direction of the Plate Surface (Pillow Shape)
9-Apri-2009

34. 349-Apri-2009

35. Fig. 6.5: The result of Experiment No. 4
359-Apri-2009

36. 36
2. Longitudinal Concave Curvature Shape with Twist (Expr.5) Plate
Dims. 12X1500X900 mm.
9-Apri-2009

37. 379-Apri-2009

38. Fig. 6.6: The result of Experiment No. 5
389-Apri-2009

39. 39
 Experiments of Reverse Double Curvature Shape (Saddle
Shape)
1. Longitudinal Convex Curvature Shape without Twist (Expr.6)
Plate Dims. 10X1500X870 mm.
9-Apri-2009

40. 409-Apri-2009

41. Fig. 6.7: The result of Experiment No. 6
419-Apri-2009

42. 42
2. Longitudinal Convex Curvature Shape with Twist (Expr.7) Plate Dims.
12X1500X900 mm.
9-Apri-2009

43. 439-Apri-2009

44. Fig. 6.8: The result of Experiment No. 7
449-Apri-2009

45. 45
 Experiments of Double Curvature Shape due to Twist on the Plate
Surface (Expr.8) Plate Dims. 10X5343X2283 mm.
9-Apri-2009

46. Fig. 6.9: The result of Experiment No. 8
469-Apri-2009

47. 7. CONCLUSION
47
8. RECOMMENDATIONS FOR FUTURE WORK
9-Apri-2009

48. ?
QUESTIONS
489-Apri-2009

49. 499-Apri-2009

50. THANK YOU
509-Apri-2009