CERN -LHC- 99-004-CRT EUROPEAN ORGANIZATION FOR NUCLEAR RESEARCH 3940 Laboratory for Particle Physics me Divisional Report CERN LHC/99-07 (CRI) Low-cycle fatigue induced buckling of eryogenic pipelines in the light of ductile damage mechanics B. Skoczen, Z. Tokarz* Stability of pressurised pipelines containing expansion joints and subjected to large temperature variations is highly affected by the low-cycle fatigue phenomena. The bellows axial stiffness is a direct consequence of evelopment and accumulation of localised plastic strain fields in the shell convolutions. A. gradual decrease of the bellows axial stiffness (creep-lke effect) leads eventually either to local buckling of the bellows itself or to global buckling of the pipeline, Effect of fetigue on axial stiffness of thin corrugated shells can be explained via the ductile damage mechanics, that means plastic strain induced deterioration of the material. In order to analyse this process a material model based on the plasticity with linear kinematic hardening was used. The numerical procedure is based on the correction of the material moduli after each cycle due to the current value of the ‘damage parameter (associated with the accumulated plastic strain). * Lodz University of Technology, Poland ‘CERN LIBRARIES, GENEVA SCAN-9910028 Aaminiraive Sere Geneva, Switzerland vision ae 30 August 1999 CH- 1211 Geneva 23EDMS No: 102559 LOW-CYCLE FATIGUE INDUCED BUCKLING OF CRYOGENIC PIPELINES IN THE LIGHT OF DUCTILE DAMAGE MECHANICS B. Skoczen', Z. Tokarz* ' LHC Division, CERN, Geneva, Switzerland * Lodz University of Technology, Poland Sabiity of pressurised pipelines containing expansion joins and subjected to large temperature variations is highly affected by the Iow-cyce fatigue phenomena, The bellows axial stiffness is a direct consequence of development and accumulation of localised plastic strain fields in the shell convolutions, A gradual decrease of the bellows axial stiffness (creep-like effect) leads eventually either to local buckling of the bellows itself or to global buckling of the pipeline. Effect of fatigue on axial stiffness of thin corrugated shells can be explained via the ductile damage mechanics, that means plastic strain induced deterioration of the material. In order to analyse this process a material model based on the plasticity with linear kinematic hardening was used. The numerical procedure is based on the correction of the material moduli ater each cycle due to the current value ofthe damage parameter (associated with the accumulated plastic strain). Key Words: Mechanical stability, cryogenic pipelines, bellows, low-cycle fatigue, ductile damage 14/04/1999 L Introduction ‘Thermo-mechanical stability of pressurised pipelines containing expansion joints is determined by the bellows-to-pipe stiffness ratio, A pipeline segment equipped with an expansion joint shall be regarded as a slender column containing an elasto-plastic hinge of highly nonlinear characteristics that depend on temperature. Moreover, a sirong coupling between the bellows stiffness and thermo-mechanical cycling is observed (Ref. [1]). A creep-like deterioration of the bellows axial stiffness leads to premature failure (buckling) of a pipeline. This particular effect is amplified by the low-eyele fatigue phenomena, which ecur in the pipelines containing relatively short bellows when compared to thermal cexpansion/contraction of tubes. ‘The effect of fatigue on the stiffness of thin corrugated shells can be explained via the ductile damage mechanics, that means plastic strain induced deterioration of the material. ‘The micro-voids and tmicro-cracks development in ductile materials, represented by the damage parameter D. leads 10 decrease of the modulus of elasticity & as well as the yield point Oy and the hardening modulus 1. ‘This effect results in a global softening of the pressurised shell and finally in buckling. The evolution of damage is given by the following law (Refs [2,3]) o-(sle " where ¥ denotes the energy density release rate, $ the strength enerey of damage, whereas p stands for the accumulated plastic strain pe k[S Development of localised plastic zones in the bellows convolutions (depending on the temperature 7) and corresponding accumulation of damage lead to @ considerable reduetion of the bellows axiat stiffness F,(D) and, finally, t0 decrease of bucking pressure: 2 2a @ where L denotes the length of bellows convolutions, A similar reasoning may be applied to pipeline segments ‘where the bellows-to-pipe stiffness ratio decreases. 2 Buckling of pipelines at cryogenic temperatures A typical mode of buckling of @ pressurised Pipeline segment containing an expansion joint is showa in Fig. 1. In order to caleulate the corresponding. buckling pressure a model of elastically supported equivalent column was developed (Fig.2, Ref. (4)) ‘The bending stiffness of the column is equal to thebending stiffness of bellows whereas the stiffness of springs is equivalent to the bending stiffness of the portions of tubes between the supports and the bellows, ends. — = Figure 1: Buckling of a pipeline segment ‘The appropriate eigenvalue problem takes the form of the following transcendental equation: 2-[+(ys twaXI- HEEL feast) + ® (ew tH E(w, Hw PE esn( tt) 0 where AL-are the eigenvalues, eee 2 x L yi w Figure 2: The equivalent colurnn with elastically supported ends ‘Thus, the buckling load of a pipeline segment is given 3) where B denotes the bending sti and: ness of the column baal sp-% ro) The buckling load depends strongly onthe temperature. The material properties of grade 316 L. stainless steel at room and at eryogenie temperatures (Ref. [5) are shown in Table 1, Since both the ‘modulus of elasticity and the yield strength increase at low temperauures the development of local plastic strain fields in the bellows corrugations is reduced, This leads to enhanced axial and bending stiffness and to a higher buckling loa. ‘Table 1: Mechanical properties of 316 L stainless steel “Temperature | Yield Tensile | Elongation kK) Sueog | Stength ( (MPa) (MPa) 300 216 529 © 7 314 1235 ao a BL 1441 48 3 Simplified models of monotonic and cyctic plasticity in the light of ductile damage mechanics 3.1 ‘THE ELASTO-PLASTIC MATERIAL WITH LINEAR KINEMATIC HARDENING ‘The following model was used to calculate intensity of the local strain fields (Ref. (1)) ‘The strains (e ~ elastic, p~ plastic, T — thermal) ey =ejtepeer a where ef << ef,ef and 65 = €)(T). ef = ef (T) ‘The elastic stresses (with G = G(T) ): 5) = 2G.e5 (ej ~ deviatoric strain) p24 95, =2G0-Dye =26e, (8) where G, denotes the effective deviatoric stress. Definition of the yield surface (with o, =o 4(T)) 0 (19) where a, denotes the back stress. Evolution of the centre of the yield surface (with C = C(T)) Cée? > da, = C(l-Dydep ay deg ‘The above-presented constitutive equations are derived as a modification of the classical formulation with the following substitutive moduli G=G-D), 6, =0,0-D),E=Cl-D) (12) 3.2 INCREMENT OF DAMAGE ON CYCLE (PERFECTLY PLASTIC MATERIAL) In order to simplify the analysis of damage evolution under cyclic loads the model of elasto ~ perfectly plastic material is used:=o, } Ot aelT) «aay 1-D ‘The kinetic law of damage evolution (Ret. [3)) ok, ),, uy 2ES (1 D)? where R, denotes the triaxiality ratio, is integrated ‘over one cycle: my sin dh as) 7 vp ou BES (= DY? to calculate the increment of damage per cycle. Here te following assumptions sre made © Parameter s=1 ‘+ Damage evolution is identical under tension and compression + et >>et + deformation i incompressible v = 0.5 With these assumptions ene obtains: ES} where ff, determine one half of the cycle (Fig.3) eae co —_——+ «? oe 4 Figure 3: One half of the eyele (f, 2) If the hysteresis loops are stabilised the damage parameter after N cycles is equal to: an a2 (% Dy = sen ( 2 seca) = ef | Say Ap ot 22k ES’ ES ee [YBevera-] fer where Ap is calculated for the first stable eycle, 4 Numerical analysis ~ hysteresis loops and damage evolution In order to use the existing finite element codes the following procedure was applic + Finite element model of half pitch of the bellows convolution was made and subdivided into 5 areas (1-2 at root, 3-central, 4-5 at crest) Simulation of the first 20. thermo-mechanical cycles (loads: pressure, temperature and cyclic displacement) was carried out with the effect of cyclic hardening accounted for. + ‘The assumption was made that the hysteresis loops stabilise after first 20 cycles and onset of damage ( p > pp } is observed. + The accumulated plastic strain Ap! is calculated for each subsequent cycle in each area (i=1,5) and the corresponding updated damage levels are computed (Dy, )- ‘+ After each cycle the material moduli (Eq, 12) are modified accordingly. + Also a special damage parameter Dy is calculated at root (the largest intensity of plastic strains) and the process is terminated if Dg, = 0.8 (assumed critical value of damage). A typical set of global hysteresis loops (20 cycles) at room and at cryogenic temperatures is shown in Fig. 4. Displacement mm} Figure 4: Force-displacement loops at 300K, 77K, 4K The stabilised hysteresis loops at 300K and the corresponding damage evolution is shown in Figs 5, 6 ‘| Figure 5: Stabilised hysteresis loops (light grey) at 300KOne obtains similar curves for the temperature of liquid nitrogen 77K and liquid helium 4K, cop a = Nopdes Figure 6: Evolution of damage at 300K: 1-2 at root, 3- central part, 4-5 at crest, 6 ~ max. value at root ‘5 Fatigue induced buckling of pi (Coupling fatigue/stability) Development of damage (micro-cracks, micro. voids) in the bellows convolutions leads 10 a significant reduction of bellows stiffness (Fig.7). Both the tangent stiffness, measured as the unloading slope, and the secant stiftness, measured between the loop extreme points, decrease with the number of cycles thus leading to a premature instability of the pipeline, Figure 7: Evolution of the tangent stiffness (three ‘upper curves) and the secant one (lower curve) at 4K after N cycles Analysis of buckling of pipeline segments is carried ‘out on the basis of Eq. 4, Here the mean tangent stiffness (unloading in both points of return) was used as the bellows axial stiffness. The stability curves for a typical pipeline segment working at 4K are presented in Fig. 8. The upper set of curves shows stability of the Pipeline after 20 cycles whereas the lower set shows, its stability after 93 eycles with the accumulation of damage. The horizontal curves I correspond 10 the primary buckling mode {only bellows buckles) ‘whereas the vertical curves 2 correspond to the pipeline buckling mode, shown in Fig, 1. 1 PalPeo om a ' 0 gets ] : oa eles router eu titcetaes Pen ee eer 1. Figure 8: Mechanical stability of a pipeline segment at 4K after 20 and 93 cycles (normalised buckling pressure versus dimensionless length of pipes) 6 Conclusions ‘The effect of fatigue on buckling of thin corrugated shells (bellows) and pipeline segments cannot be explained on the basis of the classical theory of plasticity. The ductile damage mechanics, which explains the phenomena of evolution of micro-cracks and micro-voids in the materials, appears to be a powerful tool to estimate the buckling susceptibility after N cycles. The analysis, based on a finite element model of the bellows convolutions, is also applicable to cryogenic temperatures. This procedure was used es {4 part of the optimisation program of the bellows expansion joints developed for Large Hadron Collider (LHC) at CERN. References (1) Tolarz, Z., Skoczen, B., Effect Of Low Cycle Fatigue On ‘The Mechanical Stability Of Cryogenic Pipelines In The Light Of Ductile Damage Mechanics, MSc Thesis, Cracow University of Technology, 1998, In Polish 2) Lemaitre, £, A Course On Damage Mechanics, Springer Verlag, 1992, () Lemaite, J, Sermage, 1P., One Damage Law For Different Mectanisms, Comp. Mech., 20, p. 84, 1997. G) Skoczen, B., Effect OF Shear Deformation And Relaxation OF Support Conditions On Elastic Buckling Of Pressurised Expansion Bellows, ASME Journal of Pressure Vessel Technology accepted for publication, 1999, (5) Suzuki, K, Fukakura, I, Kashiwaya, H., Cryogenic Fatigue Propestics OF 304L And 316L Stainless Steels... J. of Test. and Eval., JTEVA, Vol.16, p. 190, 1988.