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1.optimum Autofrettage Pressure in Thick Cylinders PDF
1.optimum Autofrettage Pressure in Thick Cylinders PDF
ABSTRACT
1.0 INTRODUCTION
*
Corresponding author: E-mail: amran@fkm.utm.my
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Jurnal Mekanikal, December 2007
For a cylinder subjected to an internal pressure, Pi, the radial stress, σr, and
circumferential stress, σθ, distributions are given by Lame’s formulation:
Pi ⎡ r2⎤
σθ = ⎢ 1 − o2 ⎥ (1)
k −1 ⎣
2
r ⎦
and
Pi ⎡ ro 2 ⎤
σθ = 1 + (2)
k 2 − 1 ⎢⎣ r 2 ⎥⎦
For a cylinder with end caps and free to change in length, the axial stress is
given by [5]:
Pi
σz = (3)
k −1
2
According to the Tresca yield theory, yielding occurs when the Tresca
equivalent stress is [5]:
σ Tr = (σ θ − σ r ) = σ Y (4)
Based on the von Mises yield theory, yielding occurs when the von Mises
equivalent stress is [6]:
σvM =
1
2
{ 2
}
(σθ − σr ) + (σr − σz ) + ( σz − σθ ) = σY
2 2
(5)
Two important pressure limits, PY,i and PY,o , are considered to be of importance
in the study of pressurised cylinders. PY,i corresponds to the internal pressure
required at the onset of yielding at the inner surface of the cylinder, and PY,o is
the internal pressure required to cause the wall thickness of cylinder to yield
completely. The magnitudes of PY,i and PY, o, according to Tresca yield criterion
are, [2], [6], [7]:
(k 2 - 1 )
PTr,Y ,i = σY (6)
2k 2
(k 2 - 1 )
PTr,Y,o = σY (7)
2
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Jurnal Mekanikal, December 2007
and based on the von Mises yield criterion, the magnitudes of PY, i and PY, o are,
[2]:
(k 2 - 1 )
PvM ,Y ,i = σY (8)
3k 2
(k 2 - 1 )
PvM ,Y ,o = σY (9)
3
Equations (4) and (5) give the relation between the von Mises and Tresca
equivalent stresses for the state of stress in a pressurised thick-walled cylinder:
3 3
σ vM = ( σθ − σ r ) = σTr (10)
2 2
and shows that the Tresca criterion is more conservative than the von Mises
criterion by 15.5 %.
If the internal pressure is removed after part of the cylinder thickness has
become plastic, a residual stress is set up in the wall. Assuming that during
unloading the material follows Hooke’s Law, the residual stresses can be
obtained from the equations below. For the plastic region, ri ≤ r ≤ ra, the
respective residual stresses in the radial, hoop and axial directions are [8]:
For the elastic region, ra ≤ r ≤ ro , the respective residual stresses in the radial,
hoop and axial directions are:
σY ⎡ ro2 ⎤ ⎧⎪ m2 ⎛ m2 ⎞ ⎛ 1 ⎞⎫⎪
σr,e, R =
2 ⎢1− r2 ⎥ ⎨ k 2 − ⎜1− k 2 + 2ln ( m) ⎟ ⎜ k 2 −1 ⎟⎬ (12a)
⎣ ⎦ ⎩⎪ ⎝ ⎠⎝ ⎠⎭⎪
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Jurnal Mekanikal, December 2007
σY ⎡ ro2 ⎤ ⎪⎧ m2 ⎛ m2 ⎞ ⎛ 1 ⎞⎪⎫
σθ,e, R = ⎢1+ 2 ⎥ ⎨ 2 − ⎜1− 2 + 2ln ( m) ⎟ ⎜ 2 ⎟⎬ (12b)
2 ⎣ r ⎦ ⎪⎩ k ⎝ k ⎠ ⎝ k −1 ⎠⎪⎭
σY ⎧⎪m2 ⎛ m2 ⎞ ⎛ 1 ⎞⎫⎪
σz, e, R = ⎨ 2 − ⎜1− 2 + 2ln ( m) ⎟⎜ 2 ⎟⎬ (12c)
2 ⎩⎪ k ⎝ k ⎠ ⎝ k −1⎠⎭⎪
ra
where m = and ra is the autofrettage radius. By substituting r = ra in
ri
Equations (12a-c), the residual stresses at the junction radius ra are obtained:
σY ⎡ k2 ⎤ ⎪⎧m2 ⎛ m2 ⎞ ⎛ 1 ⎞⎪⎫
σr, R = ⎢1− m2 ⎥ ⎨ k2 − ⎜1− k 2 + 2ln ( m) ⎟⎜ k2 −1⎟⎬ (13a)
2 ⎣ ⎦ ⎩⎪ ⎝ ⎠⎝ ⎠⎭⎪
σY ⎡ k 2 ⎤ ⎪⎧m2 ⎛ m2 ⎞ ⎛ 1 ⎞⎪⎫
σθ,R = ⎢1+ 2 ⎥ ⎨ 2 − ⎜1− 2 + 2ln ( m) ⎟⎜ 2 ⎟⎬ (13b)
2 ⎣ m ⎦ ⎩⎪ k ⎝ k ⎠ ⎝ k −1⎠⎭⎪
⎪⎧ m ⎡ m ⎤ ⎛ 1 ⎞⎪⎫
2 2
σY
σz, R = ⎨ 2 − ⎢1− 2 + 2ln ( m)⎥ ⎜ 2 ⎟⎬ (13c)
2 ⎪⎩ k ⎣ k ⎦ ⎝ k −1⎠⎪⎭
2.20E+08
1.80E+08 σθ
σθ,T
1.40E+08
1.00E+08
Stress [MPa]
6.00E+07
2.00E+07
-2.00E+07 0.1 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.2
-6.00E+07
σθ,R
-1.00E+08
-1.40E+08
Plastic Region Elastic Region
-1.80E+08
ri
-2.20E+08
Radius in cylinder wall [m] ro
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Jurnal Mekanikal, December 2007
2.20E+08
1.00E+08
σθ.R
Stress [MPa]
6.00E+07
2.00E+07
-2.00E+07 0.1
σr,R
0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.2
-6.00E+07
-1.00E+08
-1.40E+08
σz,R
Plastic Region Elastic Region
-1.80E+08
-2.20E+08
ri Radius in cylinder wall [m] ro
1.80E+08
σθ,T
1.40E+08
1.00E+08
σz,T
Stress [MPa]
6.00E+07
2.00E+07
-2.00E+07 0.1 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.2
-6.00E+07
-1.00E+08
σr,T
-1.40E+08
Plastic Region Elastic Region
-1.80E+08
-2.20E+08
ri Radius in cylinder wall [m] ro
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Jurnal Mekanikal, December 2007
mTr
Optimum autofrettage / ri (mopt)
2.5
2
mvM
1.5
0.5
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Operating pressure / Yield stress (n)
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Jurnal Mekanikal, December 2007
Equations (6) and (7) are used to obtain the (Tresca) autofrettage pressure to
cause different stages of yielding in a virgin cylinder. For a cylinder treated
with partial autofrettage, the internal pressure to cause the inner surface to yield
again can be obtained. Substituting Equations (1), (2) and (12) into Equation
(14), and using Tresca yield criterion, when r = ri , the internal pressure to cause
yielding at the inner surface is,
σY ⎡ m2 ⎤
PY, i = ⎢ 2ln ( m ) + 1 − 2 ⎥ (19)
2 ⎣ k ⎦
and when r = ro , by substituting Equations (1), (2) and (11) into Equation (14),
and using Tresca yield criterion, the internal pressure to cause the whole wall
thickness to yield is,
σY
PY, o = ⎡2ln ( m) + k 2 − m2 ⎤⎦ (20)
2 ⎣
Figures 5 and 6 respectively show the maximum internal pressure to cause
yielding at the inner surface and to cause the whole cylinder to yield. These
pressures are influenced by different optimum autofrettage pressure levels
which were obtained when an operating pressure was initially known. The
internal pressure to cause yielding at the inner surface of a cylinder which is
treated with optimum autofrettage pressure, is greater than that for a non-treated
cylinder (Figure 5). On the other hand, the internal pressure to cause full
yielding in a cylinder which has been treated with optimum autofrettage, is
lower than that which is non-autofrettaged (Figure 6).
2
Maximum internal pressure / Yield stress
1.5 0.2
-- 0.25
0.3
-- 0.35
0.4
-- 0.45
0.5
-- 0.55
1
Optimum Autofrettage 0.6
-- 0.65
0.7
-- 0.75
0.8
-- 0.85
0.9
-- 0.95
Non-Autofrettage
0.5
0
1.2
2.4
3.5
4.7
5.8
7.0
8.1
9.3
10.4
11.6
12.7
13.9
15.0
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Jurnal Mekanikal, December 2007
stress [n]
0.7
0.6
5 0.5
2 Optimum Autofrettage
0
1.2 1.5 1.8 2.1 2.4 2.7 3 3.3 3.6
Radius ratio [k]
A special case is when the cylinder is fully autofrettaged, i.e. ra = ro. Therefore
m = k and the Tresca equivalent stress at any radius can be obtained from
Equation (15):
Therefore the internal pressure to cause the internal surface and whole wall to
yield is obtained by substituting r = ri, r = ro and m = k in Equations (19) and
(20). The comparison of allowable internal pressures of a cylinder treated with
full and non-autofrettage, are shown in Table 1 and in Figures 7 and 8. Figure 7
shows that full autofrettage is beneficial if yielding of the inner surface is
required, in which case the cylinder can sustain the highest internal pressure. To
cause the whole wall to yield, the cylinder should not be autofrettaged, in which
case the cylinder can sustain the highest internal pressure, as shown in Figure 8.
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Jurnal Mekanikal, December 2007
1.8
Fully- Autofrettaged
1.6
Internal Pressure/Yield stress [n]
1.4
1.2
1
0.916
0.8
0.6
Non-Autofrettaged
0.4 0.420
0.2
4
3.5
3
2.625
2.5
2
1.5 Fully- Autofrettaged
1
0.916
0.5
0
1.3 1.6 1.9 2.2 2.5 2.8 3.1 3.4
Radius Ratio [k]
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Jurnal Mekanikal, December 2007
σY ⎡ r2 ⎛ r ⎞⎤
P= ⎢1− + 2ln ⎜ ⎟⎥ (22)
2 ⎣ ro2 ⎝ ri ⎠⎦
From Equations (17) and (18) the optimum autofrettage radius is deduced as,
ra, opt = ri e n - Tresca
3
n
ra, opt = ri e 2
- von Mises
Therefore the optimum autofrettage pressure is:
σY ⎡ e 2n ⎤
Pa, opt, Tr = ⎢1 − k 2 + 2n ⎥ - Tresca (23)
2 ⎣ ⎦
σY ⎡ e 3n ⎤
Pa, opt, vM = ⎢1 − 2 + 3n ⎥ - von Mises (24)
2 ⎣⎢ k ⎥⎦
The above optimum autofrettage pressures result in the minimum equivalent
stress and occurs on the elastic-plastic junction line as shown in Figure 9.
Equivalent stress at junction line/Yield stress
ri 100 mm
ro 200 mm
k 2
Po 130 MPa
σY 325 MPa
n 0.4
r a, opt 149.18 mm
P a, opt 202 MPa
σ eq 239 MPa
The relation between the optimum autofrettage pressure and operating pressure
of thick-walled pressurised cylinders can be obtained:
Pa ,o p t,T r ⎡ k 2 − e 2n ⎤
= ⎢1 + - Tresca (25)
Po p r ,T r ⎣ 2 n k 2 ⎥⎦
Pa ,o p t,vM ⎡ 3 k2 − e 3n
⎤
= ⎢ + ⎥ - von Mises (26)
Po p r,v M ⎣⎢ 2 nk 2 ⎦⎥
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Jurnal Mekanikal, December 2007
E = 203 GPa
σY = 325 MPa
ν = 0.33
10.0 CONCLUSIONS
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Jurnal Mekanikal, December 2007
4) If the yield stress, σY, is large, the optimum boundary radius (ra,opt) is small.
5) The optimum autofrettage pressure causes the lowest equivalent stress
during application of operating pressure, and this occurs at the elastic-
plastic junction line.
6) The optimum autofrettage radius, ra,opt depends on the operating pressure
Popr, and the inner radius of the thick-wall cylinder ri, apart from the
material property σY.
NOMENCLATURE
P pressure
r radius
t thickness
k outer:inner radius ratio
m autofrettage:inner radius ratio
n operating pressure:yield stress ratio
σ normal stress
τ shear stress
Subscripts
i inner
o outer
a autofrettage
r radial
θ hoop
z axial
Y yield
p plastic
e elastic
opt optimum
opr operating
max maximum
min minimum
Tr Tresca
vM von Mises
R residual
T total
REFERENCES
1. Thumser, R., Bergmann, J.W., Vormwald, M., 2002. Residual stress fields
and fatigue analysis of autofrettage parts, Int Jnl Pressure Vessels and
Piping, 79(2), 113-117.
2. Perry, J., Aboudi, J., 2003. Elastic-plastic stresses in thick-walled cylinders,
ASME Jnl Pressure Vessel Technology, 125, 248-252.
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Jurnal Mekanikal, December 2007
3. Zhao, W., Seshadri, R., Dubey, R.N., 2003. On thick-walled cylinder under
internal pressure, ASME Jnl Pressure Vessel Technology, 125, 267-273.
4. Wang Zhiqun, 1995. Elastic-plastic fracture analysis of a thick-walled
cylinder, Int Jnl Pressure Vessels and Piping, 63, 165-168.
5. Mott, R.L., 2002. Applied Strength of Materials, New Jersey, Ohio:
Prentice Hall.
6. Hill, R., 1967. The mathematical theory of plasticity, Oxford University
Press.
7. Chaaban, A., Barake, N., 1993. Elasto-plastic analysis of high pressure
vessels with radial cross-bores, High Pressure Technology, ASME Pressure
Vessel and Piping; 263, 67-123.
8. Wuxue, Z., Zichu, Z., 1985. An elastic-plastic analysis of autofrettage
thick-walled cylinders, Proc Int Conf on Non-Linear Mechanics, Shanghai,
663-667.
9. ABAQUS v6.5.1, 2005. Getting started/Standard User’s Manual.
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