2010 SECTION Vill, DIVISION 2 ANNEX 5.A LINEARIZATION OF STRESS RESULTS FOR STRESS CLASSIFICATION (INFORMATIVE) 5.A1 Scope This Annex provides recommendations for post-processing of the results from an elastic finite element stress analysis for comparison to the limits in paragraph 6.2.2 5.A2 General a) In the finite element method, when continuum elements are used in an analysis, the total stress distribution is obtained. Therefore, to produce membrane and bending stresses, the total stress distribution shall be linearized on a stress component basis and used to calculate the equivalent stresses. If shell elements (shell theory) are used, then the membrane and bending stresses shall be obtained directly from shell stress resultants. b) Membrane and bending stresses are developed on cross sections through the thickness of a component. ‘These sections are called stress classification planes (SCPs). In a planar geometry, a Stress Classification Line (SCL) is obtained by reducing two opposite sides of a SCP to an infinitesimal length SCPs are fiat planes that cut through a section of a component and SCLs are straight lines that cut through a section of a component. SCLs are surfaces when viewed in an axisymmetric or planar geometry. Examples of an SCP and SCL are given in Figure 5.A.1 and Figure 5.4.2. (©) The following three approaches are provided for linearization of finite element results, 1) Stress Integration Method - This method can be used to linearize stress results from continuum finite element models (Ref. WRC-429} 2) Structural Stress Method Based on Nodal Forces ~ This method is based on processing of nodal forces, and has been shown to be mesh insensitive and correlate well with welded fatigue data [Ref. WRC-474} 3) Structural Stress Method Based on Stress Integration ~ This method utilizes the Stress Integration Method, but restricts the set of elements that contribute to the line of nodes being processed, 4) The Structural Stress Method based on Stress Integration is recommended unless another method can be shown to produce a more accurate assessment for the given component and loading condition, This method matches the Structural Stress Method Based on Nodal Forces, which is insensitive to mesh refinement. In addition, this method can be performed with post-processing tools typically provided by commercial finite element analysis software. 5.A.3 Selection of Stress Classification Lines a) Pressure vessels usually contain structural discontinuity regions where abrupt changes in geometry, material or loading occur. These regions are typically the locations of highest stress in a component. For the evaluation of failure modes of plastic collapse and ratcheting, Stress Classification Lines (SCLs) are typically located at gross structural discontinuities. For the evaluation of local failure and fatigue, SCLs are typically located at local structural discontinuities. 5.872010 SECTION VIII, DIVISION 2 b) For SCLs that span a material discontinuity (e.g. base metal with cladding), the SCL should include all materials and associated loadings. If one of the materials, such as cladding, is neglected for strength calculations, then only the base metal thickness should be used to calculate the membrane and bending stresses from the linearized forces and moments across the full section for the evaluation of plastic collapse. c) To most accurately determine the linearized membrane and bending stresses for comparison to elastic stress limits, the following guidelines should be followed. These guidelines can be used as a qualitative means to evaluate the applicability of different SCLs. Failure to comply with any of these criteria may not produce valid membrane andlor bending stresses. Application of the limit load or elastic-plastic analysis methods in Part § is recommended for cases where elastic stress analysis and stress linearization may produce ambiguous results. 1) SCLs should be oriented normal to contour lines of the stress component of highest magnitude. However, as this may be difficult to implement, similar accuracy can be obtained by orienting the SCL normal to the mid-surface of the cross section. SCL orientation guidelines are shown in Figure 5.A3. 2) Hoop and meridional component stress distributions on the SCL should be monotonically increasing or decreasing, except for the effects of stress concentration or thermal peak stresses, see Figure 5A3D, 3) The distribution of the through-thickness stress should be monotonically increasing or decreasing For pressure loading the through-thickness stress should be equal to the compressive pressure on the applied surface, and approximately zero on the other surface defining the SCL (see Figure 5.A.3.c). When the SCL is not perpendicular to the surfaces, this requirement will not be satisfied 4) The shear stress distribution should be parabolic and/or the stress should be low relative to the hoop and meridional stresses. Depending on the type of loading, the shear stress should be ‘approximately zero on both surfaces defined by the SCL. Guidelines are provided in Figure 5.4.3.4 i) The shear stress distribution along an SCL will approximate a parabolic distribution only when the inner and outer surfaces are parallel and the SCL is normal to the surfaces. If the surfaces are not parallel or an SCL is not normal to the surfaces, the appropriate shear distribution will not be obtained. However, if the magnitude of shear stress is small as compared to the hoop (or meridional stresses, this orientation criterion can be waived, ji) When the shear stress distribution is approximately linear, the shear stress is likely to be significant, 5) For pressure boundary components, the hoop or meridional stresses typically are the largest magnitude component stresses and are the dominant terms in the equivalent stress. Typically the hoop or meridional stresses deviate from a monotonically increasing or decreasing trend along an SCL if the SCL is skewed with respect to the interior, exterior, or mid surfaces. For most pressure vessel applications, the hoop or meridional stresses due to pressure should be nearly linear. 5.A4 Stress Integration Method 5.4.4.1 Continuum Elements BAS 1 Overview Stress results derived from a finite element analysis utlizing two-dimensional or three-dimensional continuum elements may be processed using the stress integration method. Stress components are integrated along SCLs through the wall thickness to determine the membrane and bending stress components. The peak stress components can be derived directly using this procedure by subtracting the membrane plus bending stress distribution from the total stress distribution. Using these components, the equivalent stress shall be computed per Equation (5.1). 5-582010 SECTION VIII, DIVISION 2 5.A4.1.2 Stress Linearization Procedure The methods to derive the membrane, bending, and peak components of a stress distribution are shown below, and in Figure 5.A.4. The component stresses used for the calculations shall be based on a local coordinate system defined by the orientation of the SCL, see Figure 5.4.2. a) STEP 1 ~ Calculate the membrane stress tensor. The membrane stress tensor is the tensor comprised of the average of each stress component along the stress classification line, or: 1 =! AA im feet (oat) b) STEP 2 ~ Calculate the bending stress tensor. 1) Bending stresses are calculated only for the local hoop and meridional (normal) component stresses, and not for the local component stress parallel to the SCL or in-plane shear stress, 2) The linear portion of shear stress needs to be considered only for shear stress distributions that result in torsion of the SCL (out-of-plane shear stress in the normal-hoop plane, see Figure 5.A.2) 3) The bending stress tensor is comprised of the linear varying portion of each stress component along the stress classification line, or: 6F t oy =Sfo,[4-x]ae Az wena] Al ) (a2) c) STEP 3—Caleulate the peak stress tensor. The peak stress tensor is the tensor whose components are equal to Sit Vos = FY h-g (Com Fis (6A3) Oe), =F (Dh, “(Sin Fis) (6A4) d) Step 4 ~ Calculate the three principal stresses at the ends of the SCL based on components of membrane and membrane plus bending stresses, ©) Step 5 ~ Calculate the equivalent stresses using Equation (6.1) at the ends of the SCL based on components of membrane and membrane plus bending stresses. 5.A.4.2 Shell Elements 5.A421 Over Stress results derived from a finite element analysis utilizing two-dimensional or three-dimensional shells are ‘obtained directly from the analysis results. Using the component stresses, the equivalent stress shall be ‘computed per Equation (5.1) 5.A.4.2.2 Stress Linearization Procedure ‘The methods to derive the membrane, bending, and peak components of a stress distribution are shown below. a) The membrane stress tensor is the tensor comprised of the average of each stress component along the stress classification line, or. 5-592010 SECTION Vill, DIVISION 2 AS) b) The bending stress tensor is the tensor comprised of the linear varying portion of each stress component along the stress classification line, or: (A6) ©) The peak stress tensor is the tensor whose components are equal to: Sym + Oys\(Ky =I) a7) 5.A.5 Structural Stress Method Based on Nodal Forces 5.A.5.1 Overview Stress results derived from a finite element analysis utilizing continuum or shell elements may be processed using the Structural Stress Method based on nodal forces. The mesh-insensitive structural stress method provides a robust procedure for capturing the membrane and bending stresses and can be directly utilized in fatigue design of welded joints. With this method, the structural stress normal to a hypothetical cracked plane lat a weld is evaluated. For typical pressure vessel component welds, the choice of possible crack orientations is straightforward (e.g. toe of fillet weld). Two alternative calculation procedures for the structural stress method are presented for continuum elements; a procedure based on nodal forces and a procedure based on stress integration. A typical finite element continuum model and stress evaluation line for this type of analysis is shown in Figure 5.A.5. 5.4.5.2 Continuum Elements a) Stress results derived from a finite element analysis utlizing two-dimensional or three-dimensional Continuum elements may be processed using the structural stress method and nodal forces as described below. The membrane and bending stresses can be computed from element nodal internal forces using the equations provided in Table 5.A.1. The process is illustrated in Figure 5.4.6. This method is recommended when internal force results can be obtained as part of the finite element output because the results are insensitive to the mesh density. b) When using three-dimensional continuum elements, forces and moments must be summed with respect to the mid-thickness of a member from the forces at nodes in the solid model at a through-thickness ‘cross section of interest. For a second order element, three summation lines of nodes are processed along the element faces through the wall thickness. The process is illustrated in Figure 5.A.7. ©) For a symmetric structural stress range, the two weld toes have equal opportunity to develop fatigue cracks. Therefore, the structural stress calculation involves establishing the equilibrium equivalent membrane and bending stress components with respect to one-half of the plate thickness. The equivalent structural stress calculation procedure for a symmetric stress state is illustrated in Figure 5AS. 5-602010 SECTION VIII, DIVISION 2 5.A.5.3 Shell Elements a) Stress results derived from a finite element analysis utilizing shell elements may be processed using the structural stress method and nodal forces. The membrane and bending stresses can be computed from element nodal internal forces using the equations provided in Table 5.4.2. A typical shell model is illustrated in Figure 5.4.9. b) When using three-dimensional shell elements, forces and moments with respect to the mid-thickness of ‘a member must be obtained at a cross section of interest. The process is illustrated in Figure §.A.10. 5.A.6 Structural Stress Method Based on Stress Integration As an altemative to the nodal force method above, stress results derived from a finite element analysis, utlizing two-dimensional or three-dimensional continuum elements may be processed using the Structural Stress Method Based on Stress Integration. This method utilizes the Stress Integration Method of paragraph 5.A.3, but restricts the set of elements that contribute to the line of nodes being processed. The elements applicable to the SCL for the region being evaluated shall be included in the post-processing, as is ilustrated in Figure 5.4.11 5.A7 Nomenclature s, structural stress do, structural stress range. line force at element location position nodal force at node j, normal to the section. nodal force at node, normal to the section, for element location position i in-plane nodal moment at node j , normal to the section, for a shell element. ‘nodal force resultant for element location position fatigue strength reduction factor used to compute the cyclic stress amplitude or range. m, line moment at element location position. n number of nodes in the through-wall thickness direction. M, ‘nodal moment resultant for element location position o, membrane stress. o, bending stress. o, stress tensor at the point under evaluation. Sym membrane stress tensor at the point under evaluation. yy bending stress tensor at the point under evaluation. up peak stress component. Fm stress tensor on the inside surface of the shell. Fon stress tensor on the outside surface of the shell Ou membrane stress for element location position oy bending stress for element location position | ¥, radial coordinate of node j for an axisymmetric element. 5-61BOD oS TS x 2010 SECTION Vill, DIVISION 2 local coordinate, parallel to the stress classification line, that defines the location of nodal force primary equivalent stress. secondary equivalent stress. local X axis, oriented parallel to the stress classification line local ¥ axis, oriented normal to the stress classification line. global X axis. global ¥ axis. ‘minimum wall thickness in the region under consideration, or the thickness of the vessel, as applicable. width of the element to determine structural stresses from Finite Element Analysis. through-wall thickness coordinate, 5-625A8 Tables 2010 SECTION Vill, DIVISION 2 Table 5.4.1 — Structural Stress Definitions For Continuum Finite Elements Element Type | Membrane Stress Bending Stress Two-Dimensional Axisymmetrio ‘Second Order (8- Node) Continuum Elements Two-Dimensional ‘Second Order Plane Stress or Plane Strain (8- Node) Continuum Elements Thres- Dimensional ‘Second Order (20-Node) Continuum: Elements Note: f, represents the line force corresponding to the element location positions (/ = 1,2,3) along the element width (w ); position i =2 corresponds to the mid-side of the element (see Figure 5A): 36F, +27, -F,) 2w 32F +26, -3F) Inthe above, F;,F, . and F, are the ‘nodal force resultants (producing normal membrane stress to Section A-A) through the thickness and along the width (»”) of the group of elements F=>F, | summed over the nodes from j = 1,7 | (umber of nodes in the through-thickness | direction) at Section A-A (see Figure | 5AT) Note: m, represents the line moment corresponding to the element location positions (i= 1,2,3) along the element | width (1); position = 2 corresponds to the mid-side of the element (see Figure BAT) 6M, +2M, 2w | =3(2M, +2M,-3M,) | aw | 3(2M, + 6M, ~M,) | 2w Inthe above, M,,M, ,and M, are the ‘nodal moment resultants (producing normal bending stress to Section A-A) calculated based on nodal forces with respect to the mmid-thickness (s,) along the width (w) of the group of elements M,=S0NF, summed over the nodes from j= I,m (number of nodes in the through-thickness direction) at Section A-A (see Figure 5.A.7) 5-632010 SECTION VIII, DIVISION 2 Table 5.A.2 - Structural Stress Definitions For Shell Or Plate Finite Elements, Element Type Three-Dimensional Second Order (8- Node) Shelt Elements Membrane Stress | Note: represents the force corresponding tothe element | location positions (i = 1,2,3) along the element width (w ); position i=2 corresponds to the mid-side of the element (see Figure 5.4.10): (NF, + 6NF, - NF.) 2w Inthe above, NF,,.NF; , and NF, are the internal nodal forces (in the | direction normal to Section A-A) from the shell model along a weld (see | Figure 5.A.10) [ Bending Stress om, t — oy Note: m, represents the moment corresponding to the element location | positions ( =1,2,3) along the element width (w ); position i= 2 corresponds to the mid-side of the element (see Figure 5.4.10) 3(6NMi+ 2NM3~NM2) 2w | ~3(2NMi+2NM3-3NM2) aw 3(2NMi+ 6NM2~NM2) " 2w Inthe above, NM,,NM, , and NM, are the internal nodal moments (producing normal bending stresses to Section A-A) from the shell model along a weld (see Figure 5.A.10) Three-Dimensional First Order (4- o Sue Node) Shell ma Elements Note: m, represents the moment Note: f° represents the force corresponding to the element comer corresponding to the element comer | node jocation positions (i = 1,2) along node location postions (/=1,2) | ee siren wath (or) along the element width (w): | Sova | _20NR-NF,) | m, =22NM,- NM) | —— | ‘Axisymmetric 7 Linear and Parabolic Shell Finite Element 5-642010 SECTION Vill, DIVISION 2 5.A9 Figures Stress Classification Line (SCL) and Stress Classification Plane (SCP) 5-65,2010 SECTION VIII, DIVISION 2 (a) SCL Orientation, Three- Normal Hoop Mid-plane (©) SCL Orientation, Two-Dimensional Model Figure 5.A.2 1m Lines (SCLs) 5-662010 SECTION VIII, DIVISION 2 SCL normal to maximum stress Non-monotonic ~ SCL normal to example mid-surface Monotonically increasing or decreasing ‘example (a) Example of SCL Orientation (b) Hoop and Meridional Stress Conditions (©) Through-thickness Stress (@) Shear Stress Conditions Conditions Figure 5.8.3 Stress Classification Line Orientation and Validity Guidelines 5-672010 SECTION Vill, DIVISION 2 Stress Distribution Transformed to y,> direction Figure 5.4.4 Computation of Membrane and Bending Equivalent Stresses by the Stress Integration Method Using the Results from a Finite Element Model with Continuum Elements 5-682010 SECTION Vill, DIVISION 2 hey ze / comet ont wth et 4 elements should we be orthogonal to nt head As Wetd Joi { 7 butt joint 4 {@) Component Geometry (b) Fite Element Mesh ‘Stress Evaluation Line A Wal Toe (c) Section A.A Stress Classification Line Figure 5.5 Continuum Finite Element Model Stress Classification Line for the Structural Stress Method 5-692010 SECTION Vill, DIVISION 2 Interal Nodal Forces (NF) Transformed to local coordinate system W Element Width for 30 continuum) Elements Orthogonal to Stress. Evaluation Line Figure 5.A.6 1n of Membrane and Bending Equivalent Stresses by the Structural Stress Method Using Nodal Force Results from a Finite Element Model with Continuum Elements 5-702010 SECTION Vill, DIVISION 2 | eament rosa | Inert Po : is it 161,23 folowing iso sz ist anes weld toe ure 5.A.7 Processing Nodal Force Results with the Structural Stress Method Using the Results from a Finite Element Model with Three Dimensional Second Order Continuum Elements 5-712010 SECTION VIII, DIVISION 2 Structural Stress os Tension a (a) Symmetric Structural Stress State (symmetric joint and symmetric loading) ‘Structural Stress Range 4 Ags HESS (b) Anti-symmetric Structural Stress State (symmetric joint and anti-symmetric loading) SCL at fillet weld toe (extends ZY across one-half of the thickness) ad a = at7 7 (c) Example of Symmetric Joint (double plate lap fillet weld) Figure 5.4.8 Processing Structural Stress Method Results for a Symmetric Structural Stress Range 5-722010 SECTION Vill, DIVISION 2 ~ Shell Model at Mean Radius of Nozzle and Shell Nozzle Thickness ~~ | | | | J Weld Leg | Weld Throat Thickness (see Note 1) Stress Evaluation Point | Head Thickness ~~ Note 1: The thickness and material properties of the shell element used to model the fillet weld should be established based on producing an equivalent stiffness of the actual fillet weld Figure 5.9 Computation of Membrane and Bending Equivalent Stresses by the Structural Stress Method Using the Results from a Finite Element Model with Shell Elements 5-732010 SECTION Vill, DIVISION 2 ‘See Detall A weld toe | NF1-NF3 Transformed to Y, | direction A Figure 5.4.10 Processing Nodal Force Results with the Structural Stress Method Using the Results from a Finite Element Model With Three Dimensional Second Order Shell Elements 5-742010 SECTION Vill, DIVISION 2 Element set | processed for nozzle SCL Nozzle Neck SCL Element set — processed for shell SCL Shell SCL Eromentset | | | processed for | | thick plate SCL Thick Plate SCL Thin Element set oe processed for | thin plate SCL | AY | Ly] Figure 5.A.11 Element Sets for Processing Finite Element Nodal Stress Results with the Structural Stress Method Based on Stress Integration 5-752010 SECTION VIII, DIVISION 2 ANNEX 5.B HISTOGRAM DEVELOPMENT AND CYCLE COUNTING FOR FATIGUE ANALYSIS (INFORMATIVE) 5.B1 General This annex contains cycle counting procedures required to perform a fatigue assessment for irregular stress or strain versus time histories. These procedures are used to break the loading history down into individual cycles that can be evaluated using the fatigue assessment rules of Part 5. Two cycle counting methods are presented in this Appendix. An alternative cycle counting method may be used if agreed to by the Owner- User. 5.8.2 Definitions ‘The definitions used in this Annex are shown below. a) Event ~The Users’ Design Specification may include one or more events that produce fatigue damage. Each event consists of loading components specified at a number of time points over a time period and is repeated a specified number of times. For example, an event may be the startup, shutdown, upset condition, or any other cyclic action. The sequence of multiple events may be specified or random. b) Cycle - A cycle is a relationship between stress and strain that is established by the specified loading at a location in a vessel or component. More than one stress-strain cycle may be produced at a location, either within an event or in transition between two events, and the accumulated fatigue damage of the stress-strain cycles determines the adequacy for the specified operation at that location. This determination shall be made with respect to the stabilized stress-strain cycle, ¢) Proportional Loading ~ During constant amplitude loading, as the magnitudes of the applied stresses vary with time, the size of Mohr's circle of stress also varies with time. In some cases, even though the size of Mohs circle varies during cyclic loading, if the orientation of the principal axes remains fixed, the loading is called proportional. An example of proportional loading is a shaft subjected to in-phase torsion and bending, where the ratio of axial and torsional stress remains constant during cycling. d)_Non-Proportional Loading — if the orientation of the principal axes are not fixed, but change orientation during cyclic loading, the loading is called non-proportional. An example of non-proportional loading is @ shaft subjected to out-of-phase torsion and bending, where the ratio of axial and torsional stress varies continuously during cycling. @) Peak - The point at which the first derivative of the loading or stress histogram changes from positive to negative, f) Valley ~ The point at which the first derivative of the loading or stress histogram changes from negative to positive. 5.B.3 Histogram Development 5.B.3.1 The loading histogram should be determined based on the specified loadings provided in the Users’ Design Specification. The loading histogram should include all significant operating loads and events that are applied to the component. The following should be considered In developing the loading histogram. a) The number of repetitions of each event during the operation life. 5-76