Text Eq.

refers to Mechanical Engineering Design, 7

th
edition text by Joseph Edward Shigley, Charles
R. Mischke and Richard G. Budynas; equations and figures with the prefix T refer to the present tutorial.
MECHANICAL ENGINEERING DESIGN
TUTORIAL 4 15: PRESSURE VESSEL DESIGN


PRESSURE VESSEL DESIGN MODELS FOR CYLINDERS:

1. Thick-walled Cylinders
2. Thin-walled Cylinders

THICK-WALL THEORY

Thick-wall theory is developed from the Theory of Elasticity which yields the state of
stress as a continuous function of radius over the pressure vessel wall. The state of
stress is defined relative to a convenient cylindrical coordinate system:

1.
t
Tangential Stress
2.
r
Radial Stress
3.
l
Longitudinal Stress

Stresses in a cylindrical pressure vessel depend upon the ratio of the inner radius to
the outer radius ( /
o i
r r ) rather than the size of the cylinder.
Principal Stresses (
1 2 3
, , )

1. Determined without computation of Mohrs Circle;
2. Equivalent to cylindrical stresses ( , ,
t r l
)

Applicable for any wall thickness-to-radius ratio.

Cylinder under Pressure

Consider a cylinder, with capped ends, subjected to an internal pressure, p
i
, and an
external pressure, p
o
,











FIGURE T4-15-1
o
p
o
r
i
r
i
p

l

Shigley, Mischke & Budynas Machine Design Tutorial 415: Pressure Vessel Design 2/10

The cylinder geometry is defined by the inside radius, ,
i
r the outside radius, ,
o
r and the
cylinder length, l. In general, the stresses in the cylindrical pressure vessel ( , ,
t r l
)
can be computed at any radial coordinate value, r, within the wall thickness bounded by
i
r and ,
o
r and will be characterized by the ratio of radii, / .
o i
r r = These cylindrical
stresses represent the principal stresses and can be computed directly using Eq. 4-50 and
4-52. Thus we do not need to use Mohrs circle to assess the principal stresses.

Tangential Stress:

2 2
2 2 2 2 2
/ ) (
i o
i o o i o o i i
t
r r
r p p r r r p r p

= for
i o
r r r (Text Eq. 4-50)

Radial Stress:

2 2
2 2 2 2 2
/ ) (
i o
i o o i o o i i
r
r r
r p p r r r p r p

+
= for
i o
r r r (Text Eq. 4-50)

Longitudinal Stress:

Applicable to cases where the cylinder carries the longitudinal load, such as
capped ends.
Only valid far away from end caps where bending, nonlinearities and stress
concentrations are not significant.

2 2
2 2
i o
o o i i
l
r r
r p r p

= for
i o
r r r (Modified Text Eq. 4-52)

Two Mechanical Design Cases

1. Internal Pressure Only ( 0 =
o
p )
2. External Pressure Only ( 0 =
i
p )

Design Case 1: Internal Pressure Only

Only one case to consider the critical section which exists at
i
r r = .
Substituting 0 =
o
p into Eqs. (4-50) and incorporating / ,
o i
r r = the
largest value of each stress component is found at the inner surface:

2 2 2
,max
2 2 2
1
( )
1
o i
t i t i i i ti
o i
r r
r r p p p C
r r

+ +
= = = = =

(T-1)

Shigley, Mischke & Budynas Machine Design Tutorial 415: Pressure Vessel Design 3/10

where
2 2 2
2 2 2
1
1
o i
ti
o i
r r
C
r r

+ +
= =

is a function of cylinder geometry only.
i r i r
p r r = = =
max ,
) ( Natural Boundary Condition (T-2)

Longitudinal stress depends upon end conditions:



i li
p C Capped Ends (T-3a)
l
=
0 Uncapped Ends (T-3b)


where
2
1
1
li
C

.

Design Case 2: External Pressure Only

The critical section is identified by considering the state of stress at two
points on the cylinder: r = r
i
and r = r
o
. Substituting p
i
= 0 into Text
Eqs. (4-50) for each case:

r = r
i
0 ) ( = =
i r
r r Natural Boundary Condition (T-4a)

( )
2 2
,max
2 2 2
2 2
1
o
t i t o o o to
o i
r
r r p p p C
r r

= = = = =

(T-4b)
where,
2 2
2 2 2
2 2
1
o
to
o i
r
C
r r

= =

.
r = r
o

o r o r
p r r = = =
max ,
) ( Natural Boundary Condition (T-5a)
2 2 2
2 2 2
1
( )
1
o i
t o o o o ti
o i
r r
r r p p p C
r r

+ +
= = = =

(T-5b)

Longitudinal stress for a closed cylinder now depends upon external
pressure and radius while that of an open-ended cylinder remains zero:


o lo
p C Capped Ends (T-6a)
l
=
0 Uncapped Ends (T-6b)

Shigley, Mischke & Budynas Machine Design Tutorial 415: Pressure Vessel Design 4/10

where
2
2
1
lo
C

.

Example T4.15.1: Thick-wall Cylinder Analysis

Problem Statement: Consider a cylinder subjected to an external pressure of
150 MPa and an internal pressure of zero. The cylinder has a 25 mm ID and a 50
mm OD, respectively. Assume the cylinder is capped.

Find:
1. the state of stress (
r

,

t

,

l
) at the inner and outer cylinder
surfaces;
2. the Mohrs Circle plot for the inside and outside cylinder surfaces;
3. the critical section based upon the estimate of
max

.


Solution Methodology:
Since we have an external pressure case, we need to compute the state of
stress ( ,
r

,
t

l
) at both the inside and outside radius in order to determine
the critical section.
1. As the cylinder is closed and exposed to external pressure only,
Eq. (T-6a) may be applied to calculate the longitudinal stress
developed. This result represents the average stress across the wall
of the pressure vessel and thus may be used for both the inner and
outer radii analyses.
2. Assess the radial and tangential stresses using Eqs. (T-4) and (T-5)
for the inner and outer radii, respectively.
3. Assess the principal stresses for the inner and outer radii based
upon the magnitudes of ( ,
r

,
t

l
) at each radius.
4. Use the principal stresses to calculate the maximum shear stress at
each radius.
5. Draw Mohrs Circle for both states of stress and determine which
provides the critical section.

Solution:

1. Longitudinal Stress Calculation:

OD 50 mm ID 25mm
25mm; 12.5mm
2 2 2 2
o i
r r = = = = = =

Compute the radius ratio,
25 mm
2.0
12.5 mm
o
i
r
r
= = =

Shigley, Mischke & Budynas Machine Design Tutorial 415: Pressure Vessel Design 5/10

Then,
2 2
2 2
2
2
2
(2)
1 (2) 1
( ) ( ) ( 150MPa)(1.3333 mm )
1
lo
l i l o o o lo
C
r r r r p p C

= = =

= = = = = =

2
1.3333 mm
MPa 200 = == =
l


2. Radial & Tangential Stress Calculations:

Inner Radius (r = r
i
)
2 2
2 2
2
,max 2 2
2 2(2)
1 (2) 1
2
( ) ( 150MPa)(2.6667)
to
o
t i t o o to
o i
C
r
r r p p C
r r

= = =

= = = = =

2.6667

400 MPa
t i
! (r r ) Compressive = =

0 p for Condition Boundary Natural
i
= = = 0 ) r (r !
i r


Outer Radius (r = r
o
)
2 2
2 2
2 2
,min 2 2
1 (2) 1
1 (2) 1
( ) ( 150MPa)(1.6667)
ti
o i
t o t o o ti
o i
C
r r
r r p p C
r r

+ +
= = =

+
= = = = =

1.6667

e Compressiv MPa 250 = == = = == = ) r (r !
o t

Condition Boundary Natural MPa 150 = == = = == = = == =
o i r
p ) r (r !

3. Define Principal Stresses:

Inner Radius (r = r
i
) Outer Radius (r = r
o
)

MPa 400
MPa 200
MPa 0
3
2
1
= =
= =
= =
t
l
r




MPa 250
MPa 200
MPa 150
3
2
1
= =
= =
= =
t
l
r





4. Maximum Shear Stress Calculations:

Inner Radius (r = r
i
)
1 3
max
0 ( 400)
( )
2 2
i
r r

= = = = 200 MPa

Shigley, Mischke & Budynas Machine Design Tutorial 415: Pressure Vessel Design 6/10

Outer Radius (r = r
o
)
1 3
max
( 150) ( 250)
( )
2 2
o
r r

= = = = 50 MPa

5. Mohrs Circles:

Inner Radius (r = r
i
)
















Outer Radius (r = r
o
)

















Critical Section

! Radius Inside at is Section Critical r r
i
= == = = == = MPa 200 ) (
max

1
150 MPa =
3

= -250 MPa


2
= -200 MPa

max
= 50 MPa

2
= -200 MPa
3

= -400 MPa

1
0 MPa =
max

= 200 MPa

FIGURE T4-15-2
FIGURE T4-15-3

Shigley, Mischke & Budynas Machine Design Tutorial 415: Pressure Vessel Design 7/10

THIN-WALL THEORY

Thin-wall theory is developed from a Strength of Materials solution which yields the
state of stress as an average over the pressure vessel wall.
Use restricted by wall thickness-to-radius ratio:

1
According to theory, Thin-wall Theory is justified for
20
t
r


1
In practice, typically use a less conservative rule,
10
t
r


State of Stress Definition:

1. Hoop Stress,
t
, assumed to be uniform across wall thickness.
2. Radial Stress is insignificant compared to tangential stress, thus, 0.
r

3. Longitudinal Stress,
l

S Exists for cylinders with capped ends;
S Assumed to be uniformly distributed across wall thickness;
S This approximation for the longitudinal stress is only valid far away
from the end-caps.

4. These cylindrical stresses ( , , )
t r l
are principal stresses ( , , )
t r l
which
can be determined without computation of Mohrs circle plot.

Analysis of Cylinder Section

1
t
F
V
F
Hoop
F
Hoop
Pressure Acting over
Projected Vertical Area
d
i
FIGURE T4-15-4

Shigley, Mischke & Budynas Machine Design Tutorial 415: Pressure Vessel Design 8/10

The internal pressure exerts a vertical force, F
V
, on the cylinder wall which is
balanced by the tangential hoop stress, F
Hoop
.

t pd F F F
t t A F
pd d p pA F
t i Hoop V y
t t stressed t Hoop
i i proj V

= = =
= = =
= = =
2 2 0
)} 1 )( {(
)} 1 )( {(


Solving for the tangential stress,
Hoop Stress
2
i
t
pd
t
= (Text Eq. 4-53)
Comparison of state of stress for cylinder under internal pressure verses external
pressure:
Internal Pressure Only
2
0
(Text Eq. 4-55)
4 2
i
t
r
i t
l
pd
Hoop Stress
t
By Definition
pd
Capped Case
t

=
=
= =

External Pressure Only
2
0
4 2
o
t
r
o t
l
pd
Hoop Stress
t
By Definition
pd
Capped Case
t

=
=
= =



Example T4.15.2: Thin-wall Theory Applied to Cylinder Analysis


Problem Statement: Repeat Example T1.1 using the Thin-wall Theory
(p
o
= 150 MPa, p
i
= 0, ID = 25 mm, OD = 50 mm).

Find: The percent difference of the maximum shear stress estimates found using
the Thick-wall and Thin-wall Theories.



Shigley, Mischke & Budynas Machine Design Tutorial 415: Pressure Vessel Design 9/10

Solution Methodology:

1. Check t/r ratio to determine if Thin-wall Theory is applicable.
2. Use the Thin-wall Theory to compute the state of stress
3. Identify the principal stresses based upon the stress magnitudes.
4. Use the principal stresses to assess the maximum shear stress.
5. Calculate the percent difference between the maximum shear stresses
derived using the Thick-wall and Thin-wall Theories.

Solution:
1. Check t/r Ratio:
10
1
20
1
2
1
mm 25
mm 5 . 12
or
r
t
= =

The application of Thin-wall Theory to estimate the stress state of this
cylinder is thus not justified.

2. Compute stresses using the Thin-wall Theory to compare with Thick-
wall theory estimates.

definition by Stress Radial b.
mm) 2(12.5
) mm 50 )( MPa 150 (
2
wall) across uniform stress, (average Stress Hoop a.
r
0
MPa 300
=
=

t
d p
o o
t

c. Longitudinal Stress (average stress, uniform across wall)
4 2
o o t
l
p d
t

= = = 150 MPa

3. Identify Principal Stresses in terms of Average Stresses:

MPa 300
MPa 150
MPa 0
3
2
1
= =
= =
= =
t
l
r





4. Maximum Shear Stress Calculation:

MPa 150
2
) MPa 300 ( 0
2
3 1
max
+ =

=

=



5. Percent Difference between Thin- and Thick-wall Estimates for the
Critical Section:


Shigley, Mischke & Budynas Machine Design Tutorial 415: Pressure Vessel Design 10/10

max,Thin max,Thick
max,Thick
% 100%
( 150) ( 200)
(100%)
( 200)
Difference

=
+ +
= =
+
25%


Thin -wall estimate is 25% low!