NOTICE! This metorial may be protected ¢ Copyright lew (ity 17, U.S. ANALYSIS OF TUBE-TUBESHEET JOINTS WITH GROOVES D. P, Updike and A. Kalnins Department of Mechanical Engineering and Mechanics Lehigh University Bethlehem, Penneyivania S. M. Caldwell Eastman Kodak Company Kingsport, Tennessee ABSTRACT Hydraulic expansion of a grooved tube nto a tubeshect 1s modeled aa an elastic-plastic process. A shell mode of the tube Js sullatly modited to tnelude the effect of radiol otress ia the yield condition and the effeel of the resiatance from contact with th tubesheet The tbesheet 1s modcled as an elastic- plasuc foundavion. The loading and unloading snalyals of the ‘tube subjected to expansion presmre an the inside auritee and twbesheet restscance on the outside surface ta perfarmed to determine the reedual state in he vicinity of the grooves. The parameters investigated are the residual holding pressure between the ke and the tubeshest and the stresses in the contact and noncontact regions af the tube, NOMENCLATURE, x ex) coordinate 2 thickness coordinale; 220 on reference surCace @ excumferentiol coordinate R radius of reference surface tp 2, Fevordinales of saner and outer urfaces of tube Rakes Ryoho, Inner and outer radll of tube Pj Py Pressure at inner and outer urces of tube ‘w radial displacement af a point ta. the tbe i eeal displacement of polnt ta the tube By, rotation of normal cy. ¢g components of san at reference surface pq components of curvature change @, wanarerec shear free per unit reumierence Nj Ng membrane stross resultents Mj-Mg, bending moment per uni Yength Oye Ogy 0, Components ofstresa tae €, components of trata ‘cofnponents of clastic strain typ" Fay Components of patie strain E Young's modulus -v Polastn's ratio equivalent plastic tram 3,.8_ Feducad etresees 1g, Kinematic tmin harriening parameters ¥ leotropie strain hardening parameter Yo nia ye stress pw nulxed hardening coeMctent. ,, Plastic modes xe! “Oe taner rastus of annulus model of tubeaheet outer radius of annulus model of tubesheet Pressure at hole i tubeshect rudd dsplacoment at hole i tubeshect INTRODUCTION ‘The transition zone at the edge of w tube-tubesheet Joint ta a location of significant residual stresa thet is Induced during the fabrication precess of expanding the tube (1.2.81. A major coniribulor te an andestrable axtal tenaite companent of residual stress resulls ffom the meridional bending that 19 * gasoclatod wilh diftrential radial expansion, variation of ‘capansion loading, and variation of springhack slang the tube. Another location of differeala] radial expansion occura fn the vieinlty of @ groove [4] In the iubeshest hole, where the expansion process Jeaves, a state of residual stresa that veries along the tube. Tie objective of this paper is to determine the ‘magnitude and algebraic eign of these sireseea, +Liddle aformation on a (ubs-lubeshect Jomt wilh grooves. fo available in lhe literature, Mautfacturcr's standards (41 inte that for pronsures ovcr 300 psi and/or temperatures tn exces of 350°F, tie tube holes for expanded Joints for tubes of 9/5" O.D. and langer ahall be machined with at least (wo grooves, cach approximately 1/8° wile by 1/64" dcep. No requiresnculs olt (oove spacing arc slated. Experimentally determined pushout forces for tube-ubcaliect jolule wilh grooves have ecu reported in {6}, Information oa the residual siressea In the tubes aut on the distribution of the holding pressure seems to be unavailable, This paper considers a thecrclical approach to the determination of these stresses. (MATHEMATICAL MODEL OF TUBESHEET ‘The tubeahcet Is modeled as a continuous distribution of annular disks surrounding Ore tbe. It acts ag an clastio- Plaatie foundation of Uke (ube, The taner and outer radii of = fypleal disk arc « and b, reapcctiely, where b is an ellective Cuter radiva [6) at which « boundary condition of zara radial Gtrese 19 applied. Each disk Is assutted to be expanded by a Pressure py neting ot the inae radius, act disk 9 subjected to elaatte-plaste loading, fallowct by unloading, A tincar hardening model of plasticity has boon assumed. Since the Jongitudinal atrese o, 1 aaaumod lo be vero Unroughout te tubeshect, the calculations far te behavior of a typical disk fan be corried oul usig a, computer progran which porforms Cinst plastic enalysls of at plaice, Wih the aki of & Plastic alte analysis program named KalciPL, a calculation 1s Firried out to find the radial expansion v, of the Inner cxge a fa function of the premure p, at the laner edge during elastic: plastic loading, This relation fo expressed mathematically ae p= Pt) ‘this function Js sored! In a data base for later use, (Tile data fpaoe Is the same as that which wos used tn (1.2) fer the Ciewlallon of tie restlual stresses In the wansilon zone.) To faake the data basc applicable (o many diferent tubcaliecte, Ure Giorege uses nondimensional variables in the tube-tubesiest pint problem, p, and u, are taken to be functious of the ‘coordinate x; however, Ure relation betwoen them at a given velie of xia that gen above, (GROOVE GEOMETRY there ts a radial clearance ¢ between the tube land the Uibeshcet. Whe Ure radial dleplacement of the tube ‘Guring whe inital expansion We Sess tian c, De prossure Py 18 zero. After conlact between te tube and the tubcshest is made, the presotre py, whi fs alo eal 1 pom te tube, begs 2 increase, The value of this coniact pressure teetwoen the (ube and the tubeshoot then satisfies atta, Pye Pothier) cH ‘rhe grooves In the tubeslicet were modeled by represeuling, lhe radial clearance as slep functions of the coordinate x, the sep being cqual (0 the groove deplb. The present analysis was Fecuricicd to a study of @ Cubeshorl with a repeated paticrn of Cqually spaced grooves of equal size as atiowa in Figze 1. Tae model that was used In the analysia Inelnded one lialf-groove, & ful ridge, and a oceond halfgraoe. Symmetry boundary coudilions at the gronve.centers were tse gure t. Hepcatot“Ratiarn of Eawally ‘Spaced Grooves: MATHEMATICAL MODEL OF TUBE ‘A spocial shell theory has been developed for une atidy of the (ubetubesticet problem, since the weual planc slress assumplton of shell theory does nol apply to the expansion recess, where pressure foading % on tbe order of the. yicld Tiress, ‘The special thcary uses the equiliorium equations taken fom the theny of cylladrical shelts, “These oqualons relate the morments, forces, and suriace loads an foflown: 40,/ax= N/R =(P.R,- PARR aN, fix = 0 dM fa = Oy‘The stress resuhants (or a cylindrical sWvelt are NpeSoyienide Nye Log ax M, FoyliezMinds — Mys Soy zd ‘the equations of displacement anel strain are wie = By du fx = oy TR apyexex, kyr? ‘Tac dlotrtbution of etrain through the thickness is given by acy / (terse ret K) In the spectal theory taed here, the radial atress o, 19 assumed lo vary linesrly throught the thickness of the tube, 20 that tts distrlimtion is given by 0, = tifa, # Pyeap Ea) Following the usual practice of plasiicity thcory. the components of alrain are decompose Into clastic and plastie portions eee, 5 x” Oe” Sap ‘o0* op where the clasite portions ate relaled to the siress componeme by Hoale's law Egg Og V9 VO ME tg 2 g¥O, VIVE Plasticity ts modeled by Introductug Ue loading function (von Mises yield condition with stralu hardening) glven by fo. QO, eget 2 : ssi? ¥ were veges ee ‘ep condition t 19 .19g.0,16,0,00= 0 * ‘The parameters c and c, are (he Kincwalte strain hardening parametera which Indleate the translation of the yield aurface. fnllially, their valuea ere zero. The parameter Y is the tsotrople hardening parameter. 1 imticales the expansion of the yield surface. IC 1s tnltally equal to the yield stress Yq In fenston and ovmpression. The Increments of these struin- Dardeaing paramcicrs are related to the plastic strain tneremente de, = Es, Me THE, ts de, dey +H Ep ey/MAe,, avatiy8, ue wey ty where 2 2 12 (hie edeg + de, de, P mp Sop * Sap Fo / 91 Js (he equivalent plastic strain Increment. The coefficient 1 19 equal to @0 If the strain hardening Is isotropic and equal to 10 411 te kinemaulc. Au tntcrmelate value of may be used. EXAMPLE, ‘Asan example, weconsider a unbeand tbesnest composes of materiale having the same clostic-plastic material behavior, We Itave neaumedratios of material properties as E/Y, = 1000, v= 0, H,/B = OO). These properties are represeaintve of a imumber of materials, All calculated stresses are normalized with respect (0 the common yiekt stress Yq. The following geometry, ‘which fs the same as (hat weed In {2}, Is assumed: ‘Tube aniaide diameter = 1.000 ‘Tube wal thickness = 0.0607 ‘Radial clearance at ridge = 0.0300 Radial clearance at groove » 0.0256 Depth af groove » 0.0156 ‘Wien of groove = 0.125 (Lin Fig. Width of ridge = 0.250 Uh in Fig. 1) Radhue of hole = 0.510 Eficelive outer radius of annulus = 1.020 In order to expaail the ube into Ure grooved hole, the presse p, {lhe hydraulle forming pressure} must be increased to nomic peak valle Py ax ata then be reduced to zero. This toad- lunloarl cycic bas been simulated in the model, where we Ieave, ‘this ample, assumed that 110%, Pistributlons of tress components In the tube and contact pressure at the stale of peak inlornal pressure and at the ‘ealdual alate lave been calenlaled und plotted in Figures 8-8.RESULTS Figure 2 shows a plot of the Ipteauite forming presaure 20 a funetnn of radial digplacement of the tube at the ceater of tie groove, Each mark om the curve indicates one load atcp taken ln ihe elastic-plastic process, There arc four siccp slope regions and three platcaus on the curve, The fret stesp portion Gad plateau represenls the inlial chstle-plastle expansion of lo its contacting the ridge. ‘The second ne pert hen eopioct Is made at the riige the plateau rajcatng yioking of the tubeatct at the ridge. The third sate on indicates ie sillening elect cue to contact Tee the tube and the valley of the groove! The prescuice of belvenig iatces indicaies tre tubeshect 19 alao ykiling in thy sagen The fal stzep portion indicates the unloading Regending the untoading euve, It may be noted that even thé Father weiding te nat indicald will Ihe pressure Jo almost seiercly removed, Une carve shows «alight nonlinear ffect aoe Naced by the reluction in Whe eze of the contact zone In the groove. PRESSUREMELD STRENGTH Figure 2, Hydraulic FormingPressure Versus Radial Deflection al the Center of the Groove Cinene atress at te tnatte of the lube, where sireas corrosion acking might be # problem, 1s the axial stgess at the canter of magnitude of this stress 15 "AL the outaide surface of the tube, the largest tensile residual sireas 1s the hoop slress at the cenicr of the groove, where It 1s 26% of the Initial yield stress. ” Figures 7 and & show the distrbatom of the residual contact presuré between Uke tubs and tubeshct at the start of unloading and al the fal residual stale. Figure 7 aleo shows the applled hydraulic forming pressure on (he Inside of the tube (atraight Une at the level I.1). ‘The absciice of regions of 250 contact pressure Indicates that, at the en af the load-up, Ure contact between the tube sid tubeslicet Las been made over Ui ‘whole rength of the groove. Figure 8 shows that, aflur Unloading, the tule and tubeslicct huve separated over the whole length of the groove, STRESSMELD STRENGTH ars! — Ltt ‘io ois a1 005 00 O65 aic O15 a” "ANAL DISTANGE ALONG TUSE Reatdual Avdal Stress at Insidc ‘Surface of Tube Figure 3. os 005: STRESSMELD STRENGTH a2. i “+ .., “he OF a0 005 oo acs alo 320 "AXIAL DISTANCE ALONG TUBE os Figure 4 Residual oop Stress al Inside ‘Surface of TubeDISCUSSION It is woeful to compare te residual stresses In the groove with thove im the Lransiiion zone al (he eige of the wbe- ubsshoct joint, This luformauon ts mvadable fram reference Ia}, where a ube-wibcaheet Joint of the same dimensions und mialeriat propertics was (reated. i reference (2), the maxiaium Tealdual otress at the inside surface of the Wansition zone was, found lo be 87% of the initial yield stress, compared with maximum of 32% found at the graove. : ny reference (21, the optimun forming pres: he about 78% of the fnitil yield stress. For higher values. Iitue change In fual contact aud maximum residual stress was observed. It wos obscrved In he prescut analysis (hal, whien the same kevel of firming provsure was used for the tube- ltubeshect Joint with groves, the lube Just barely made contact ‘wh dhe babesbest la the groove. This ean be socn clearly from Figure 2 where the Urd sleop portion begins. Thereiore, m1 We present analysis, a much higher forming pressure (110% of yield stress) was used.” 8 B STRESSMELD STRENGTH & 6 e 025. ri PRESSURE ie els aio 00s 000 ofS mio als am ‘AXIAL DISTANCE ALONG TUBE Figure 8. Resldual Axfol Stress al Outside Surface of Tube, @ [STRESSMMELD STRENGTH & 4 1 ‘Gm eis aio abs obo aus aio ais am ‘ARIAL DISTANGE ALONG TUBE Figure 6. Residual Hoop Suess at Outside ‘Surface of Tube as. att Sim aie io 05 oo abs o10 015 am ‘AXIAL DISTANCE ALONG TUSE Fignre7, Contact Pressure (outside surface) and Forming Pressure linskle euriace} at Cundition of Peak Formuig Pressure. | i 0102 ana fone | ais RESIDUAL CONTACT PRESSURE” =7an0 6 LL Gay 01 ain 005 060 abs aio Gis oz ‘@XULL DISTANCE ALONG TUBE Figure 8. Distrtbution of Residual Contact Prossure 6‘The plots of the stress disiribulons show the occurrence of discontinuity in the hoop areas, Tha i an expected result. Te peagon Io that the transverse stress fo the tube wall, 0, 19 discontinuous at these polnts, and satisfaction of the yicid condition on both idea of the discontinuty requires ‘acoutinutly of some other streas component, nainely the boop, tress. Since the width of Ure groove is nat large in comparison with the tube wall Uitclness, the use of a shell dicory that ls tie eflect of tanaerse shear atcsscs im the mechanical behavior may appear auspect. ‘To check that this te not the case, we calculated Ihe average Wanaverse shear sireas, Le. transverse ehear force divided by wall thickness, for the ample problem. Its value turned out to bean order of magnitude Below the other calculated stresses; thus, the use of shcil teary was judged acceptable. . Migure 9 shows the deflociion curve of the ouler surfice of the tubeal the maximum forming pressure, eupcrposcd on Uiecross ‘section of the undeformed tubesheet and the outer surface of the tube. Trom fhe distributon of the contact, pressure (Figure 7), At can be geen that there 1s complete contact between Ute tube and tubeaheel, crea at the re-eatrant corners of the groovs. ‘This means that tre deformed tubeshect touches Ute deflection une of the tube, shown In Figure 9, at cry point. This implies a discontisuous raat displaccutent in the tubeahest at the boundary of the ridge and thc groove. Such « disconumully represents an infinite alcar elrain at the corner of lhe grove. ‘Thie io a desect in the mathemalical model of Uhc tubesheet weed Ia this paper. The model assumes thin, Independently acting rings, with oo shear arose between them (ctaslic-plastic Foundation), On the other hand, the model of Uo lube assumice ‘ero transverse shcar strains, which male It inacusive to the Jnfuite strain ia the tubesboct For this reason, and atnce this paper 12 concerited wilh Uhe stresses in the tube, and sot int ihe ¢ubsahest, it 1s expectnd that this detect does not alter our smaia reaults signiNeantly. i i r 2 i LEE ZZ i it eo “a6 O10 00S -DO O05 Oo OIG O20 “ASIA. DISTANCE ALONG TUBE Yigred, Dellecllon of dbformed tube and ‘cross sections of undeformed tube and tubesheet. CONCLUSIONS ‘The resulta of this Investigation lead 16 the following conclusions: 1. For the sample problem consiered, the hlyhest tense yeakdal strest ot the Inside wurface of the (ube was ‘the axial stress at the conler of the groove. ile value was ‘about 32% of the yield sitess, which Jw small in comparison ith that found in the tramoition zone Just outside the Joint, where a reekiual strese of 87% of the yield atress ts expected. 2. A joint with grooves requires a higher forming pressure than fa Jolnt without groves. This la due to the additional fffort required to bend the (ube wall Into the grooves. No ‘iticmpt wae made tn this paper to optimize this value. REYERENCES: Uj D.P. Updike, A, Katnins, ond S. M. Caldwell, “A tod for Calculating Restival Stresvea in Transition Zoues of Heal Exchanger Tubes," ASME Bound Volume PVP - vol. 139, Design ‘and_Analynla of Piping, Pressure: Veoncis. snk Componcaa-+ 1988, edlled by Q- N. trwong. 0. N. Brooks, A A. Dermenjian, and W.E. Short if, pp. 113-118, 12] D. P. Updue, A. Kalnins, and 8. M. Caldwell, “Reskdual ‘Stresses in Transition Zones of Iical Exchanger Tubs,” ASME. Bound Volume PVP - vol. 175, a ‘ollted by G. N jbo, G. E. O. Widera, and M. Shiratorl, pp. Brooks, H. Obi 30-44, JS J. Drucz, A Bazergul, and M. J. Pettigrew, ‘Hesidual Stresses in Roller-Expanded Thin Tubes," Experimental Mechantes, vel. 24, 1984, pp. SLG- 924. 14] Tubular Exchanger Manufacturers Associaiton, we. Slandands ‘of Tubular Emchengcr Manufoctursr Asmsfalian, stellt ‘edition, 1978. 151M. H. Jawad, Z, J, Clarkin, and R. . Schuessler, ‘Evaluation of Tube-lo-Tubcsbect , Joints.” Journal of Presaure Yesscl Technology, Trams. “ASME, vol. 109, Feb. 1984, pp. 19-20. [61 ¥, Wang and A. L Soler, “Effect of Boundary Conditions ot the Tube-Tubeshest Anmults Model - Pintle Exement Analysts ASME Bound Volume PVP - Vol. 139, = 1388, (eaite! by Q. N. Truong, G. N. Brooks, A. A, Desmcajian, and W. Z. ‘Stioct 10, pp. 107-112.