EG-262 Stress Analysis 1

6. Cylinders Under Pressure – Thick and Compound Cylinders

6.1 Graphical Method of Solution – Lame Lines

We will now look at an alternative method of solution for thick cylinders under pressure. If we
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plot the Lame equations on 𝜎 and axes, we generate straight lines as shown below:
𝑟2

These two lines have the same slope and intercept. We can combine them into one line by
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plotting radial stress to the right of the 𝜎 axis (𝜎𝑟 against ) and hoop stress to the left of the
𝑟2
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𝜎 axis (𝜎𝜃 against − 𝑟 2 ).

For the case of a cylinder subject to both internal and external pressure:

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In most questions, two values of 𝜎𝑟 or one value of 𝜎𝑟 and one value of 𝜎𝜃 will be given
allowing Lame theory to be used by:

 Accurate drawing of lines

 Sketch of lines and similar triangles

6.2 Cylinder subject to internal pressure only

The boundary conditions are:

𝜎𝑟 = −𝑝 at 𝑟 = 𝑅𝑖

𝜎𝑟 = 0 at 𝑟 = 𝑅𝑜

Plotting this:

By similar triangles, the maximum hoop stress can be seen to be:

1 1 𝑅𝑜 2 + 𝑅𝑖 2
+
𝜎𝜃𝑚𝑎𝑥 𝑅 2 𝑅𝑜 2 𝑅 2𝑅 2 𝑅𝑜 2 + 𝑅𝑖 2 𝑅𝑖 2 𝑅𝑜 2 𝑅𝑜 2 + 𝑅𝑖 2
= 𝑖 = 2𝑖 𝑜 2 = ( ) ( ) =
𝑝 1 1 𝑅𝑜 − 𝑅𝑖 𝑅𝑖 2 𝑅𝑜 2 𝑅𝑜 2 − 𝑅𝑖 2 𝑅𝑜 2 − 𝑅𝑖 2
2− 2
𝑅𝑖 𝑅𝑜 𝑅𝑖 2 𝑅𝑜 2

𝑅𝑜 2 + 𝑅𝑖 2
𝜎𝜃𝑚𝑎𝑥 = 𝑝
𝑅𝑜 2 − 𝑅𝑖 2

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Proof of Lame line methodology:

𝜎𝑟 = −𝑝 at 𝑟 = 𝑅𝑖 , 𝜎𝑟 = 0 at 𝑟 = 𝑅𝑜

𝐵 𝐵
𝜎𝑟 = 𝐴 − and 𝜎𝜃 = 𝐴 +
𝑟2 𝑟2
Gives:

𝐵 𝐵 𝐵
𝜎𝑟 = 𝐴 − → −p = A − 2 and 0=𝐴−
𝑟2 𝑅𝑖 𝑅𝑜 2
From which:
𝐵 𝐵 𝐵 1 1 𝑅𝑖 2 − 𝑅𝑜 2
𝐴= ∴ −p = ( 2 ) − 2 = 𝐵 ( 2 − 2 ) = 𝐵 ( )
𝑅𝑜 2 𝑅𝑜 𝑅𝑖 𝑅𝑜 𝑅𝑖 𝑅𝑖 2 𝑅𝑜 2

𝑅𝑖 2 𝑅𝑜 2 𝑅𝑖 2 𝑅𝑜 2
B = −p ( 2 ) = p( 2 )
𝑅𝑖 − 𝑅𝑜 2 𝑅𝑜 − 𝑅𝑖 2
Therefore:
𝐵 1 𝑅𝑖 2 𝑅𝑜 2 𝑝𝑅𝑖 2
𝐴= = {p ( 2 )} = 2
𝑅𝑜 2 𝑅𝑜 2 𝑅𝑜 − 𝑅𝑖 2 𝑅𝑜 − 𝑅𝑖 2

For radial stress:

𝐵 𝑅𝑖 2 𝑝 𝑅𝑖 2 𝑅𝑜 2 𝑝𝑅𝑖 2 𝑅𝑜 2
𝜎𝑟 = 𝐴 − 2 = 𝑝 ( 2 )− 2( 2 )= 2 (1 − 2 )
𝑟 𝑅𝑜 − 𝑅𝑖 2 𝑟 𝑅𝑜 − 𝑅𝑖 2 𝑅𝑜 − 𝑅𝑖 2 𝑟

For hoop stress:

𝐵 𝑅𝑖 2 𝑝 𝑅𝑖 2 𝑅𝑜 2 𝑝𝑅𝑖 2 𝑅𝑜 2
𝜎𝜃 = 𝐴 + = ( ) + ( ) = (1 + )
𝑟2 𝑅𝑜 2 − 𝑅𝑖 2 𝑟 2 𝑅𝑜 2 − 𝑅𝑖 2 𝑅𝑜 2 − 𝑅𝑖 2 𝑟2

The maximum value of 𝜎𝜃 will occur when 𝑟 = 𝑅𝑖 :

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𝑝𝑅𝑖 2 𝑅𝑜 2 𝑝𝑅𝑖 2 𝑅𝑖 2 + 𝑅𝑜
𝜎𝜃 = (1 + )= ( )
𝑅𝑜 2 − 𝑅𝑖 2 𝑅𝑖 2 𝑅𝑜 2 − 𝑅𝑖 2 𝑅𝑖 2

𝑅𝑜 2 + 𝑅𝑖 2
𝜎𝜃 = 𝑝
(𝑅𝑜 2 − 𝑅𝑖 2 )

This is in agreement with the solution from the Lame lines.

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6.3 Cylinder subject to external pressure only
The boundary conditions are:

𝜎𝑟 = 0 at 𝑟 = 𝑅𝑖

𝜎𝑟 = −𝑝 at 𝑟 = 𝑅𝑜

Plotting this:

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6.4 Compound Cylinders
When a cylinder is subject to internal pressure, there is a significant variation in the hoop stress
across the wall thickness. This implies that the material of the cylinder is not being used to
maximum advantage. It is possible to obtain a more uniform hoop stress distribution by the
process of shrinking one cylinder onto the outside of another.

The inner diameter of the outer cylinder is made slightly smaller than the outer diameter of the
inner cylinder. Assembly is generally achieved by heating the outer cylinder until it can freely
slide over the inner cylinder (it is possible to cool the inner cylinder). On cooling, the outer
cylinder will contract and the inner cylinder is thus brought into a state of compression. The
outer cylinder is conversely brought into a state of tension.

If this compound cylinder is subjected to an internal pressure, the hoop stress will be the
algebraic sum of those due to the internal pressure and those due to the shrinkage. This yields
a much smaller variation in hoop stress.

The implication of this is that a compound cylinder can withstand greater internal pressures.

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6.4.1 Cylinders of the Same Material
Assuming that both cylinders are manufactured from the same material, the method of solution
can be broken down into three separate effects:

Condition 1: Shrinkage pressure on the inner cylinder only

Condition 2: Shrinkage pressure on the outer cylinder only
Condition 3: Internal pressure only on the compound cylinder

For each of the resulting load conditions, there are two known values of the radial stress which
is sufficient to determine the associated Lame constants.

Condition 1:
𝐴𝑡 𝑟 = 𝑅𝑖 , 𝜎𝑟 = 0

𝐴𝑡 𝑟 = 𝑅𝑐 , 𝜎𝑟 = −𝑝 (compressive since it tends to reduce wall thickness)

Where 𝑅𝑐 is the common radius where the cylinders mate.

Condition 2:
𝐴𝑡 𝑟 = 𝑅𝑜 , 𝜎𝑟 = 0

𝐴𝑡 𝑟 = 𝑅𝑐 , 𝜎𝑟 = −𝑝

Condition 3:
𝐴𝑡 𝑟 = 𝑅𝑜 , 𝜎𝑟 = 0

𝐴𝑡 𝑟 = 𝑅𝑖 , 𝜎𝑟 = −𝑃𝑖

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Therefore, for each condition, the hoop and radial stresses at any radius can be evaluated and
the principle of superposition applied. This means that the various stresses can simply be added
up to represent the stresses in a compound cylinder subject to both shrinkage and internal
pressure.

Lame lines can still be used to solve for compound cylinders. Vertical lines should be plotted to
represent the boundaries of the cylinder walls at their appropriate 1⁄𝑟 2 values.

The solution for Condition 3 produces a single line across both cylinder sections. Conditions 1
and 2 (the effects of shrinkage) cannot be graphically represented as a single line. They must be
treated separately and the effect on each cylinder must be determined by projection of known
lines on the radial side of the graph to the respective cylinder on the hoop stress side.

The graphs can then be added (beware of signs) to produce an overall graph. In reality we only
need to construct the combined graph. All value should be estimated by use of similar triangles.

6.5 Shrinkage or Interference Allowance

When we design a compound cylinder, we need to relate the difference in diameter of the
mating cylinders to the resultant stresses. The difference in diameter at the mating surfaces is
called the shrinkage or interference allowance for compound cylinders produced by shrinking
(normal process) or force fit procedure respectively.

Let us consider the compound cylinder shown below (the materials of the two cylinders are not
necessarily the same):

Let:

𝑝 = pressure set up at junction of cylinders due to fit

𝜎𝜃𝑖 = hoop stress on inner cylinder at junction (compressive)

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 𝜎𝜃𝑜 = hoop stress on outer cylinder at junction (tensile)

Then if:
𝛿𝑜 = radial shift of outer cylinder
𝛿𝑖 = radial shift of inner cylinder

Since the circumferential strain is equal to the diametrical strain:

𝜀𝜃 = 𝜀𝐷 (everywhere)
Then:
2𝛿𝑜 𝛿𝑜
circumferential strain at radius 𝑅 on outer cylinder = = = 𝜀𝜃𝑜
2𝑅 𝑅

2𝛿𝑖 𝛿𝑖
circumferential strain at radius 𝑅 on inner cylinder = = = −𝜀𝜃𝑖
2𝑅 𝑅

Note that 𝜀𝜃𝑖 is –ve since it represents a decrease in diameter.

Thus:

Total inteference⁄shrinkage = 𝛿𝑜 + 𝛿𝑖 = 𝑅𝜀𝜃𝑜 + 𝑅(−𝜀𝜃𝑖 ) = (𝜀𝜃𝑜 −𝜀𝜃𝑖 )𝑅

Assuming open ends (𝜎𝐿 = 0):

𝜎𝜃𝑜 − 𝑣1 (−𝑝)
𝜀𝜃𝑜 =
𝐸1
And:
𝜎𝜃𝑖 − 𝑣2 (−𝑝)
𝜀𝜃𝑖 =
𝐸2
Since:
𝜎𝑟𝑜 = 𝜎𝑟𝑖 = −𝑝

Where 𝐸1 , 𝑣1 , 𝐸2 and 𝑣2 relate to the two tubes.

Therefore, the total shrinkage or interference (based on radius) is given by:

(𝜎𝜃 + 𝑣1 𝑝) (𝜎𝜃𝑖 + 𝑣2 𝑝)
Total shrinkage (interference) = 𝑅 [ 𝑜 − ]
𝐸1 𝐸2

Where R is the initial nominal radius of the mating surfaces.

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Generally, both cylinders are of the same material:

𝐸1 = 𝐸2 = 𝐸 and 𝑣1 = 𝑣2 = 𝑣

Giving the simplified equation:

𝑅
Total shrinkage (interference) = (𝜎 − 𝜎𝜃𝑖 )
𝐸 𝜃𝑜

Note:

i. Since σθi is compressive, the sign will change

ii. Shrinkage allowance based on diameter is twice the values quoted above, with 𝑅
replaced by 𝐷

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Example:
A compound cylinder is formed by shrinking a tube of 250mm inside diameter and 300mm
outside diameter onto another smaller tube of 200mm inside diameter and 250mm outside
diameter (nominal dimensions). Both tubes are manufactured from steel. The interference
pressure at the junction is 10MPa. If the compound cylinder is then subjected to an internal
pressure of 80MPa, calculate the hoop stress distribution

Method: obtain results for shrinkage and internal pressure separately and then use
superposition to combine.

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6.6 Solid Shafts
We have the Lame equations:

𝐵 𝐵
𝜎𝑟 = 𝐴 − 𝑎𝑛𝑑 𝜎𝜃 = 𝐴 +
𝑅2 𝑅2

As 𝑅 → 0 (at the centre of the solid shaft), 𝜎𝑟 and 𝜎𝜃 → ∞! This is impossible.

Therefore, the only solution that can yield finite stress values is when 𝐵 = 0. From the above
equations, it follows that for all values of 𝑅:

𝜎𝑟 = 𝜎𝜃 = 𝐴

So at the outer surface of the shaft:

𝜎𝑟 = −𝑝 the shrinkage pressure

Thus the hoop and radial stresses throughout a solid shaft are at all points constant and equal
to the shrinkage or interference pressure and both are compressive.

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The maximum shear stress given by 2 (𝜎1 − 𝜎3 ) is therefore zero throughout the shaft.

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6.7 Force Fits
We have mentioned that compound cylinders can be manufactured by shrinking of force-fit
methods. In the case of force-fits, the interference allowance is sufficiently small to allow the
outer cylinder to be pressed (forced) over the inner cylinder with a large axial force.

Let the interference pressure set up at the common interface be 𝑝. The normal force, 𝑁,
between the mating cylinders is then:

𝑁 = 𝑝 × 2𝜋𝑅𝐿
Where:
𝑅 is the interface radius
𝐿 is the contact length

The friction force, 𝐹, that must be overcome by the applied force is thus:

𝐹 = 𝜇𝑁

Where 𝜇 is the coefficient of friction between the contact surfaces.

Therefore:
𝐹 = 𝜇(𝑝2𝜋𝑅𝐿) = 2𝜋𝜇𝑝𝑅𝐿

Is the applied force, 𝐹, is known, then the value of 𝑝 can be determined. Alternatively, if the
interference is known, 𝑝 (and hence 𝐹) can be found.

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