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Metallic Bellows
3.1 Construction of Bellows: There are mainly two types of bellows according to
manufacturing method. [20]
1. Formed bellows: The formed bellows are made from thin sheet metal. The
bellows are formed either hydraulically or mechanically, from a thin walled
tube. The tube contains longitudinal welds and exhibit significant flexibility as
the thickness is very less. Formed bellows are made in a single or multiple
plies according to requirement. The thickness of material is ranging from 0.20
to 2.5 mm and diameter of bellows from 20 mm to 3000mm. These bellows are
usually categorized according to convolution shape. Figure 3.1 shows formed
bellows and the initial thin wall tube of material.
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2. Fabricated bellows: Thin gauge diaphragms or discs are used in series and
joined by welding process. Fabricated bellows are made from heavier gauge
material than formed bellows. Hence fabricated bellows can withstand higher
amount of pressure. Figure 3.2 shows constructional arrangement of fabricated
bellows.
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Figure 3.3: Components of a bellow
COLLAR
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3.4 Convolution shapes of bellows: Bellows can be made using different
shapes of convolutions. Performance behavior of bellows differs with reference to
each convolution shape and other parameters. Mostly U shape of convolutions is
preferred by designers because of its simplicity in design, manufacturing and also
permits more amount of deformation in axial direction. Other shapes are V type, S
shape, semi toroidal shape, toroidal shape, flat, stepped, sweep, ripple etc. Figure
3.5 shows various basic shapes of convolutions. As no standard machineries are
developed for forming of convolutions, simple hydraulic or mechanical press is
used in the industries. There is no standard dimensional sizes of convolutions are
determined, and customized approach is adopted for the design there are different
features amongst various manufacturers.
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Table 3.1: Classification of Cold rolled plain carbon steels [B2]
Sr. Material Thickness Width Specification symbol /
No. designation (mm) (mm) ASTM No.
A366, A619, A620,
1 Cold rolled sheet 0.35 – 2 50 – 300
A366M, A619 M, A 620 M
A366, A619, A620,
2 Cold rolled sheet > 0.35 > 300
A366M, A619 M, A 620 M
3 Cold rolled sheet < 5.839 610 - 1220 A506, A507
The relationship between formability and values of the strain hardening exponent,
n and the plastic strain ratio ‘r’ (determined in tensile testing) is important.
Plastic strain ratio (r) is the resistance of steel sheet to thinning during forming
operations. This is the ratio of true strain in the width direction (εw ) to the true
strain in the thickness direction (ε t ) of the plastically strained sheet metal.[B2]
This rate is related to the crystallographic orientation of low carbon steels. It can
be decided by standard tension test.
The strain hardening exponent (n) is the slope of the true stress – strain curve
when plotted on logarithmic co-ordinates. A significant portion of the curve is
nearly a straight line for many low carbon steels. The approximately value is 0.22.
Many times for manufacturing of bellows annealed sheets are used as raw
material.
----------------------------------------------------------------------------------------------------------------------
B2
* ASM Hand book (Formerly metal hand book), Volume 1; Properties and selection: iron, steels
and high performance alloys; ASM International Hand Book Committee; USA; Seventh Print;
December 2005.
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Table 3.2 : Compositions of Cold rolled plain carbon steels[B2]
ASTM
Type of material C Mn P S
Specifications
CR, SQ
A 611 0.2 0.6 0.04 0.04
Grades A, B, C, E
CR, SQ
A 366 0.15 0.6 0.035 0.04
Commercial quality
CR, SQ
A 619 0.1 0.5 0.025 0.035
Drawing quality
Pressure Vessel
Grade A 0.15 0.9 0.035 0.04
Grade B 0.22 0.9 0.035 0.04
Grade C 0.25 0.9 0.035 0.04
A 414
Grade D 0.25 1.2 0.035 0.04
Grade E 0.27 1.2 0.035 0.04
Grade F 0.31 1.2 0.035 0.04
Grade G 0.31 1.35 0.035 0.04
CR = Cold Rolled, SQ = Structural Quality
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304L Stainless Steel
Type 304L is the low carbon version of Stainless steel 304. It is used in heavy
gauge components for improved weldability. Some products such as plate and
pipe may be available as “dual certified” material that meets the criteria for both
304 and 304L.
304H Stainless Steel
304H, a high carbon content variant, is also available for use at high
temperatures. Property data given in this document is typical for flat rolled
products covered by ASTM A240/A240M. ASTM, EN or other standards may
cover products sold by ‘Aalco’. It is reasonable to expect specifications in these
standards to be similar but not necessarily identical to those given in this
datasheet.
Table 3.4: Composition of SS 304[W4]
Material C Mn Si P S Cr Ni N
S S 304 0.08 max. 2.0 0.75 0.045 0.03 18-20 10.5 0.1
SS 304L 0.03 max. 2.0 0.75 0.045 0.03 18-20 12 0.1
SS 304H 0.1 max. 2.0 0.75 0.045 0.03 18-20 10.5 -
[W4]
Table 3.6: Physical Properties of Stainless steel sheets – SS 304
Property Value
Density 8.00 g/cm3
Melting point 1400-1450°C
Modulus of elasticity 193 000 MPa
Thermal conductivity 16.2 W/m.K at 100°C
Thermal expansion 17.2x10-6 /K at 100°C
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Table 3.7: Physical Properties of Inconel sheets – inconel 600
Property Value
Density 8.47 g/cm3
Melting point 1355 - 1413°C
Modulus of elasticity 207 000 MPa
Thermal conductivity 14.9 W/m.K
Thermal expansion 13.3 µm/mK
Inconel 600:
Inconel 600 is a nickel- chromium alloy with good oxidation resistance at high
temperatures and resistance to chloride ion stress corrosion cracking, corrosion
by high purity water, and caustic corrosion. It is used for furnace components, in
chemical and food processing, in nuclear engineering and for sparking electrodes.
Inconel 800:
A Ni-Cr-Fe alloy resists the high temperature oxidation. This alloy is a first choice
for an upgrade from the 300 series stainless steels when improved performance
or strength at temperature is required. For higher ASME Boiler and Pressure
Code design values, consider Alloy 800HT.
3.5.2 Properties of Inconel alloys: [W4]
1. Inconel alloys are oxidation and corrosion resistant materials well suited for
service in extreme environment.
2. When heated or at elevated temperature, inconel forms a thick, stable,
passivating oxide layer protecting the surface from further attack.
3. Inconel retains strength over a wide temperature range, attractive for high
temperature applications.
4. Inconel’s high temperature strength is developed by solid solution
strengthening or precipitation strengthening, depending on the alloy.
5. Inconel is difficult metal to shape and machine using traditional techniques
due to rapid work hardening.
6. Welding of inconel alloys is difficult due to cracking and microstructural
segregation of alloying elements in the heat affected zone. However some
alloys are designed for welding to overcome this problem.
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3.5.3 General applications of inconel sheets:
Iconel sheets are often used in extreme environments. It is common in gas turbine
blades, seals, combustors, turbocharger rotors and seals, pressure vessels, heat
exchanger tubing, etc.
Depending on the wall thickness and convolution size, single wall thin bellows
may be limited by stress or stability to lower pressure application. To overcome
this limitation, multi-ply bellows can be made by telescoping two or more cylinders
and forming together. Multi-ply bellows may be advantageous for reducing the risk
of sudden and complete failure. Also, in case of multi-ply the inner ply highly
corrosion resistance material is used and as outer ply less costly high strength
material can be used. Here, the fatigue resistance is limited by the inner ply.
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A. Multi-ply construction with the same total thickness as a single ply
construction (tt=spt)
B. Multi-ply construction with the same thickness for each ply as a single ply
construction (tt=n x spt)
C. Multi-ply construction with greater thickness for each ply than for single ply
construction (tt > n x spt)
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[20]
3.9 Internal Sleeve: Bellows can be sleeved for various reasons. First is to
reduce turbulence and thus pressure drop, to minimize erosion on the walls and to
restrict entry of foreign material. Sleeves should be designed with the minimum
practical clearance to restrict entry of foreign material. There should be sufficient
overlap at the free end to ensure that with all possible movements, especially if
lateral movement is involved, there is no chance of the sleeve end fouling the
convolutions.
Excessive hoop stress in the convoluted section of the bellows can produce
circumferential yielding and possible rupture. As in any cylindrical shell, this stress
is inversely proportional to the cross sectional areas and material properties.
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Deflection stresses are produced in the convoluted section due to deflection.
Typical stress range values are very high. These values are not true stresses,
since they exceed the elastic limit of the material. They are useful for the
prediction of fatigue life.
3.10.2 Fatigue life Expectancy: The fatigue life expectancy can be defined as
the total number of complete cycles which can be expected from the expansion
joint based on data tabulated from tests performed at room temperature under
simulated conditions. A cycle is defined as one complete movement from initial
positioning the piping system to the operating position and back to initial position.
Fatigue life is dependent upon the maximum stress range which the bellows is
subjected, the maximum stress amplitude being the far less significant factor. The
fatigue life expectancy of an expansion joint is affected by various factors such as
operating pressure, operating temperature, material of bellows, movement per
convolution, the convolution pitch, the depth and shape of the convolutions and
bellows heat treatment. Any change in these factors will result in a change of
fatigue life of the expansion joint.
The fatigue life expectancy can be evaluated from the total number of complete
cycles which can be expected from the expansion joint based on data tabulated
from tests performed at room temperature under simulated conditions.
The fatigue life of a bellows is a function of the sum of the meridional pressure
stress range and the total meridional deflection stress range. The number of
cycles to failure may be evaluated using total stress range (St) versus number of
cycles (Nc) to failure from actual fatigue tests of a series of bellows of similar
materials at room temperature. In actual practice bellows are subjected to
varieties of stress cycles during its operating life. Hence, EJMA suggests Miner’s
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hypothesis for predicting the effect of cumulative fatigue based on different stress
cycles. The relation is mentioned as follows.
n1 n 2 n3 n 4
U ..... (3.3)
N1 N 2 N 3 N 4
Where,
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depends on the kind of column. Squirm is similar to buckling of column under
compressive load. Buckling failure consists of an elastic and in-elastic region.
Since bellows are made from thin sheet metal, deformation of bellows can be in
elastic and plastic mode. Hence determination of stresses is much more difficult.
0.34 C f iu L
Buckling Pressure = Psc = 2
when b C z (3.4)
N q Db
0.87 Ac S y 0.73 Lb Lb
Buckling Pressure = Psc = 1 when Cz (3.5)
Db q C z Db Db
0.51 S i
Critical pressure, Psi = (3.6)
K2
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Squirm failure also depends on end conditions of the bellows. Normally bellows
ends are welded to collars and they are further welded to flanges of pipes.
Generally both ends rigidly fixed condition is considered. This may vary for other
application. Bellows when subjected to internal pressure is acted upon by an
unbalance pressure force or couple which, is sufficiently large, could result in
distortion of the bellows. The magnitude of the unbalance pressure force or couple
is proportional to the internal pressure and the displacement of the convolutions, a
reduction in either of these values will improve the stability of expansion joint.
3.10.4 Spring Rate of bellows: The force required to deflect a bellows axially is a
function of the dimensions of the bellows and the material from which it is made.
The flexibility of bellows is measured by spring rate of bellows. This is also helpful
for expected movement of piping for the design purpose. The curve of force
versus deflection for most bellows indicates motion extending into the plastic
range. Initially the bellow is deflected through elastic range. But as bellows
continuous and extends into plastic range, the force versus deflection relationship
becomes non-linear until the point of maximum deflection is reached.
When the restraining force is released, the curve again becomes linear until the
applied force is zero at which point the residual deflection of the bellows still has a
positive value. To return to bellows to its initial position, a restoring force must be
applied in the opposite direction as shown by the curve below abscissa.
The use of the initial elastic spring rate in place of the working spring rate for a
bellows whose deflection extends into the plastic range predicts forces which can
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be considerably higher than actual. Line B, drawn from the origin to the point of
maximum force and deflection, is used as the bellows working spring rate, fw. But
this has a disadvantage of underestimating the actual force over the full range.
Line C drawn from the point of maximum force and deflection to the value of the
restoring force required to return the bellows to zero deflection, becomes line C
when transferred to the origin. A working spring rate based on line C can be used.
This reduces the discrepancy between the indicated and true values although the
difference can still be significant. A relation to estimate the bellows theoretical
axial elastic spring rate suggested by EJMA is as follows.
3
Dm Eb t p n
Bellows theoretical axial elastic spring rate = fiu 1.7 (3.7)
w3 C f
3.10.5 Cold Springing of bellows: Actually cold springing is defined as the pre-
straining of the elements of a piping system at the time of installation, so that the
thermal stresses in the piping in the operating positions are appreciably reduced.
Foe expansion joints, cold springing is defined as the lateral or angular offset of
the ends of an expansion joint when installed and should not be considered as
axial pre-compressing or pre-extending. Where expansion joint is used to relieve
loading on sensitive equipment, or anchor structures are limited to extremely small
loads, cold springing the expansion joint at installation will effect a reduction in the
maximum deflection force value of as much as 50%. In other cases, 100% cold
spring may be used to provide minimum lateral deflection forces at the operating
position.
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K sr
Axial vibration, f n C n Hertz (3.8)
W
Where, n = 1, 2, 3, 4, 5….
1 8.84
2 9.51
3, 4 9.75
5, 6, 7, 8, 9, 10 etc. 9.81
C n Dm K sr
Lateral vibrations, f n Hertz (3.9)
Lb W
Where, C1 = 24.8 (For first mode)
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The user is asked to give basic technical information about the requirements,
pressure, temperature, maximum possible axial movement, maximum lateral
movement etc. Then according to this requirement, the manufacturer suggests the
technical design of expansion joint, which includes the dimensions and its
technical capabilities. If the user is satisfied with this design, then only commercial
aspect or rates are quoted. This approach is suggested by Expansion Joint
Manufacturing Association.
EJMA has developed theoretical stress analysis of bellows. The analysis is based
on certain assumptions. These assumptions are idealized bellow configuration, a
uniform thickness, a homogeneous and isotropic material and elastic behavior.
These assumptions are not precisely correct for most applications. A bellows
usually operates in the elastic and plastic stress region and cold work, due to
forming, alters the mechanical properties of the material.
3.13 Testing of bellows:[20] Bellows are correlated with actual test results to
demonstrate predictability of rupture pressure, meridional yielding, squirm and
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cycle life for a consistent series of bellows of same basic design. Usually, five
meridional yield rupture tests on bellows of varying sizes with not less than three
convolutions are required. A minimum of ten squirm tests on bellows of varying
diameters and number of convolutions are required. A minimum of twenty five
fatigue test on bellows of varying diameters, thicknesses, convolution profiles are
required to construct a fatigue life versus combined stress plot. The test bellows
must be representative of typical bellows design and manufacturing process.
Hence lot of cost is incurred in testing facilities of bellows. Many times special
purpose test rigs are needs to be prepared for experimental verification or testing
of bellows. Testing results can be used for the foolproof design of expansion
joints. The testing is necessary to for the verification of the design procedure.
1. Radiographic examination
5. Ultrasonic examination
1. Pressure Testing
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Following destructive tests are also recommended depending upon the
application.
1. Squirm testing
Bellows are loaded with combined tensile and compressive loadings during its
service life. Bellows may fail due following reasons during its application.
2. Fatigue failure: Bellows undergoes low cycle fatigue during its service life.
Bellows may fail due to fatigue because of its randomly occurring (different
stress ranges) thermal expansion and compression movements. The
fatigue life may be estimated based on its expected stresses due to
deflection. The bellows should be designed for finite number of life cycles.
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successive failure after squirm failure. This failure can be avoided by over
pressurization and material properties.
1. Load cells: A load cell deforms if a certain load in the form of a pressure or a
strain is imposed on it. This deformation is then detected by a strain gauge
through which a low voltage direct current is flowing. The change in voltage is
detected and made visible on a control panel. To protect this strain gauge from
outside damages or weather influences a bellow is mounted over the gauge to
protect it from outside influences.
3. Mechanical Seals: These are mostly used to close the inside of a pump from
the outside world to prevent leakage. For that purpose, a mechanical seal is
mounted on the pump shaft. As the pump shaft is turning, there has to a rotating
sealing element consisting of a stationary and a rotating ring. To enforce sufficient
pressure on the two rings one is fitted with a spring. This spring can also have the
form of a diaphragm (welded) bellow.
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the bellow can be regulated. The expansion or contraction of the bellow is used as
an actuator to control a certain movement.
6. Valve Sealing: A bellow is used between the housing and the rising stem to
seal the inside completely from the outside world. In Europe this is of particular
importance as regulations such as TA Luft prohibit any leakage.
7. Couplings for stepper motors and servomotors: The flexible part, capable of
compensating for misalignment is made by a bellow. It ensures that there is no
angular positioning difference between the two coupling halves. This is essential if
the positioning accuracy should be extremely precise.
Metal bellows are also used other products and marketplaces, including medical
applications like implantable drug pumps, to industrial actuators, to aerospace
applications such as altitude sensors and fluid management devices
(accumulators, surge arresters, volume compensators, and fluid storage). Metal
bellows are also found in space applications, providing reservoirs with potable
water as well as accumulators to collect wastewater.
2. High reliability
4. High humidity
5. Salt spray
6. Corrosive fluids
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9. Long predictable life at operating conditions
Design for strength is an essential criterion for any mechanical system. The
objective of this design is to avoid failure at minimum cross section areas for the
required loading conditions. Design of bellows, since they are made from thin
sheets, the design for thin cylinders methodology is useful. For thin cylindrical
objects with some distinguish geometric features can be designed with reference
to Barlow’s equation.
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Length of a below (Lb) = (N x p) = 33.90 cm (3.10)
Db
Thickness after thinning (tp) = t = 0.078 cm (3.13)
Dm
= 0.459 cm2
Lt
Stiffening factor (k) = = 0.925
1.5 Db x t
PDb n t Lt Eb k
2
S1 = = 4110 N/cm2 (3.15)
2n t Eb Lt Db Lt tc k Ec Lc Dc
P Dc 2 Lt Ec k
S11 = = 4160 N/cm2 (3.16)
2 n t Eb Lt Db n t tc k Ec Lc Dc
P Dm Kr
S2 = = 7137 N/cm2 (3.17)
2 n tp 0.571 2 w / q
Pw
S3 = = 740 N/cm2 (3.19)
2 n tp
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2
P w
S4 = Cp = 14220 N/cm2 (3.20)
2 n tp
Eb tp 2 e
S5 = =0 (As e = 0) (3.22)
2 w 3 Cf
5 Eb tp e
S6 = =0 (As e = 0) (3.23)
3 w 2 Cd
X 5
Axial motion per convolution, ex = = 0.34 cm (3.24)
N 15
Axial motion, X = 5 cm
Lateral motion, Y = 2 cm
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X 5
Axial motion per convolution , ex = = 0.34 m
N 15
3 Dm Y 3 x42.98 x 2
Lateral motion/convolution, ey= = =0.454 cm/con. (3.27)
N Lb X 1533.9 5
Figure 3.11 shows one layout of piping with a bellow. Bellow will be
fluctuating along X direction (towards anchor B) as the flow of fluid is in this
direction, but the expansion effect will be developed due to region between
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bellow and anchor B. The temperature of fluid will increase the temperature
of pipe materials as well as bellow. Due thermal expansion of the pipe
material, its length will be increased. Hence, thermal aspect is important in
the design of bellow. The pipe and bellow materials approach the
temperature equivalent to fluid temperature. The elastic modulus of the
bellow material is decreases at elevated temperature. Hence, an elastic
modulus should be considered at particular temperature during the design.
For the higher temperature applications, as the elastic modulus reduces, its
yield stress reduces, and finally the permissible stress limit is reduces.
Hence, the designer should control the developed stresses corresponding
to permissible stresses at designed temperature.
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Part 1: Data input:
Estimation of Stresses developed in Matallic Bellows as per EJMA
S3 S4
Num 115 Num1 25
Den 0.155506947 Num2 875.0162
S3 = Num/Den 739.52 Cp 0.65
S4 14219.01
S5 S6
Num 79553.97 Num 5115783
Den 41.3678 Den 27.7725
S5 1923.089 S6 184203.2
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3.19 Design of Components of Expansion Joints:
The basic unit of every expansion joint is the bellows. By adding additional
components expansion joints of increasing complexity and capability are created
which are suitable for wide range of applications. These components are limit
rods, lugs, hinge plates, clevis plates, flanges, collar, cover, etc. Fundamental
design rules should refer to design these components. For a specific application,
these component logical design methodology is developed as follows.
= 30 x [32.4]2 = 24740 N
4
Limit rods are used to limit the maximum movements of expansion joint as per
design. Bellow is not supposed to take up the additional expansion or contraction
movement.
Thrust load
Maximum tensile stress = (3.32)
0.785 x d 2 x no. of tie rods
24740
Diameter of tie rod = = 1.36 cm. = 15 mm
8500 x 0.785 x 2
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3.19.2 Lugs:
Lugs are provided for the support of tie rods. Normally square cross section plates
are used here. Basically it acts as a base of the tie rod assembly.
Number of lugs = 4
Section modulus = (b x t2 / 6)
247400 x 6
Cross section (b x t2) = = 45 cm.
8500 x 4
Number of hinges = 2
24740
Cross section b x t = = 1.5 cm2
8500 x 2
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3.19.4 Design of Pin
Pins are made from structural steel and its function is permit lateral and angular
motion to ends of the pipe.
24740
Pin diameter = = 1.25 cms. = 12.5 mm
2 x 0.785 x 6800 x 2
Thrust load
Crushing stress = (3.33)
X x t x no of plates
24740
Distance x = = 1.96 = 2 cms. = 20 mm
0.5 x 2 x 12750
Figure 3.12 shows schematic arrangement of clevis plate, designed for distance x.
Hinge plates are fixed at the top of support plates. The plate is under tension as
well as bending moment. Figure 3.14 shows schematic arrangement of hinge
support plates.
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h
A B
Section modulus = (b x t2 / 6)
247400 x 6
Cross Section (b x t2) = (considering 2 plates opposite sides)
12750 x 2 x 4
Gimbal ring is floated over the bellow with the support of four pins. Gimbal plates
may be square loop or circular section.
Thrust load
Cross section of gimbal plate = (b x t2 /6 )=
Permissible stress x no. of pins
24740 x10 x 6
= = 45 cm2 .
8500 x 4
24740
Pin diameter = = 0.76 cms. = 8 mm
2 x 0.785 x 6800 x 4
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Check for crushing:
Thrust load
Crushing stress =
X x t x no of plates
24740
Distance x = = 0.97 = 1 cm. = 10 mm
0.5 x 4 x 12750
Fa
Figure 3.15 shows the arrangement of pantograph linkages in the hinge type
expansion joints. The type of loading is axial due to thrust force. In one bellow,
there will be four linkages are joined by pins.
Maximum load on the each linkage will depend on the angular position, which is
achieved after expansion effects. Assuming that the angle is 450 as shown in
figure 3.16.
B
Actual link
20 cm
X cm
A 450
Fa C
Sin 450 = BC / 20
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Force on link AB = 25000 x sin 450 = 17678 N
Moment of inertia of cross section of link = (1/12) (b) (t3) = (1/12) (t) (5t) 3
= 10.416 (t4)
I 10.416 t 4
Radius of gyration; k = = = 1.44 t (3.34)
A 5t 2
fc A 100 x 5t 2
Critical load = 2
= 2
(3.35)
l 1 200
1 a 1
k 7500 1.44t
500 t 2
17678 =
2.57
1 2
t
t4
36 =
t 2 2.57
t4 – 36 t2 – 92.52 = 0
36 36 2 4 92.52
t2 = (Taking positive sign)
2
hence; t = 5.76 = 10 mm; b = 5 t = 50 mm
Ph. D. thesis on “Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation”
115
I 0.416 t 4
Radius of gyration, k = = = 0.29 t
A 5t 2
500 t 2
17678 =
15.85
1 2
t
t4
36 =
t 2 15.85
t4 – 36 t2 – 570.6 = 0
36 36 2 4 570.6
t2 = (Taking positive sign)
2
hence; t = 5.80 = 10 mm; b =5 t = 50 mm
Considering both axis the dimensions: width = 50 mm and thickness = 10 mm.
These are safe in buckling from both axes.
Note:
The designer has to keep in mind that the bellows are used for expansion and
contraction of length of pipes. No extra load or force should be transmitted on it.
Ph. D. thesis on “Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation”
116