Fretting Wear Damage of Heat Exchanger Tubes: A Proposed Damage Criterion Based on Tube Vibration Response

1998 ◽  
Vol 120 (3) ◽  
pp. 297-305 ◽  
Author(s):  
M. Yetisir ◽  
E. McKerrow ◽  
M. J. Pettigrew
Keyword(s):  
Finite Element ◽  
Heat Exchanger ◽  
Vibration Frequency ◽  
Vibration Amplitude ◽  
Work Rate ◽  
Nonlinear Finite Element ◽  
Fretting Wear ◽  
Finite Element Program ◽  
Wear Damage ◽  
The Impact

A simple criterion is proposed to estimate fretting wear damage in heat exchanger tubes with clearance supports. The criterion is based on parameters such as vibration frequency, midspan vibration amplitude, span length, tube mass, and an empirical wear coefficient. It is generally accepted that fretting wear damage is proportional to a parameter called work rate. Work rate is a measure of the dynamic interaction between a vibrating tube and its supports. Due to the complexity of the impact-sliding behavior at the clearance supports, work rate calculations for heat exchanger tubes require specialized nonlinear finite element codes. These codes include contact models for various clearance support geometries. Such nonlinear finite element analyses are complex, expensive and time consuming. The proposed criterion uses the results of linear vibration analysis (i.e., vibration frequency and mid-span vibration amplitude due to turbulence) and does not require a nonlinear analysis. It can be used by nonspecialists for a quick evaluation of the expected work rate, and hence, the fretting wear damage of heat exchanger tubes. The proposed criterion was obtained from an extensive parametric study that was conducted using a nonlinear finite element program. It is shown that, by using the proposed work rate criteria, work rate can be estimated within a factor of two. This result, however, requires further testing with more complicated flow patterns.

Impact Work-Rate and Wear of a Loosely Supported Beam Subject to Harmonic Excitation

2002 ◽  
Author(s):  
Jakob Knudsen ◽  
Ali R. Massih
Keyword(s):  
Companion Paper ◽  
Harmonic Excitation ◽  
Work Rate ◽  
Fretting Wear ◽  
Process Time ◽  
Wear Process ◽  
Stable Attractor ◽  
Wear Damage ◽  
Wear Law ◽  
The Impact

Impact work-rate of a weakly damped beam with elastic two-sided amplitude constraints subject to harmonic excitation is calculated. Impact work-rate is the rate of energy dissipation to the impacting surfaces. The beam is clamped at one end and constrained by unilateral contact sites near the other end. This system was an object of a vibro-impact experiment which was analyzed in our earlier paper (Knudsen and Massih 2000). Detailed nonlinear dynamic behavior of this system is evaluated in our companion paper (Knudsen and Massih 2002b). Computations show that the work-rate for asymmetric orbits is signifi-cantly higher than for symmetric orbits at or near the same frequency. For the vibro-impacting beam, under conditions that exhibit a stable attractor, calculation of work-rate allows us to predict the “lifetime” of the contacting beam due to fretting-wear damage by extending the stable branch and using the local gap between contacting surfaces as a control parameter. That is, upon computation of the impact work-rate, the fretting-wear process time is calculated through back-substitution of the work-rate and gap-width in a given wear law.

A Simple Energy Approach to Assess Vibration and Fretting-Wear Damage in Process Equipment

2007 ◽  
Author(s):  
Michel J. Pettigrew ◽  
Metin Yetisir ◽  
Nigel J. Fisher ◽  
Colette E. Taylor ◽  
Bruce A. W. Smith
Keyword(s):  
Heat Exchanger ◽  
Mechanical Energy ◽  
Work Rate ◽  
Energy Approach ◽  
Fretting Wear ◽  
Process Equipment ◽  
Nuclear Fuels ◽  
Heat Exchanger Tube ◽  
Wear Damage ◽  
Exchanger Tube

Excessive flow-induced vibration causing fretting-wear damage can seriously affect the performance of process equipment such as heat exchangers, condensers, nuclear steam generators, nuclear fuels, reactor internals, and piping systems. Fretting-wear damage generally takes place between a vibrating structure and its supports. It can be predicted with a fretting-wear coefficient obtained experimentally and a parameter called work-rate that formulates the dynamic interaction between structure and support. The work-rate is essentially the rate of mechanical energy dissipated at the support. On the other hand, the total available mechanical vibration energy in a structure is related to its mass, vibration frequency, mode shape, damping, and vibration amplitude. This leads to the development of a simplified formulation based on energy considerations to relate the vibration response of a structure to fretting-wear damage at its supports. The basic energy equations and the formulation of a simplified energy relationship to predict fretting-wear damage are outlined in this paper. The relationship is verified against experimental data for a multi-span heat exchanger tube. The energy approach is also compared to time domain calculations performed with a non-linear finite element code. The results indicate that the simple energy approach may be very useful to estimate fretting-wear damage in practical situations. Finally, the application of the method is illustrated for a typical heat exchanger tube and for nuclear fuels.

scholarly journals The impact of drilling and slitting construction on damage field: evolution characteristics in low-permeability coal seam

2021 ◽  
Vol 37 ◽  
pp. 205-215
Author(s):  
Heng Chen ◽  
Hongmei Cheng ◽  
Aibin Xu ◽  
Yi Xue ◽  
Weihong Peng
Keyword(s):  
Finite Element ◽  
Rock Mass ◽  
Damage Mechanics ◽  
Effective Strain ◽  
Secondary Development ◽  
Distribution Area ◽  
Finite Element Program ◽  
Element Program ◽  
Mining Face ◽  
The Impact

ABSTRACT The fracture field of coal and rock mass is the main channel for gas migration and accumulation. Exploring the evolution law of fracture field of coal and rock mass under the condition of drilling and slitting construction has important theoretical significance for guiding efficient gas drainage. The generation and evolution process of coal and rock fissures is also the development and accumulation process of its damage. Therefore, based on damage mechanics and finite element theory, the mathematical model is established. The damage variable of coal mass is defined by effective strain, the elastoplastic damage constitutive equation is established and the secondary development of finite element program is completed by FORTRAN language. Using this program, the numerical simulation of drilling and slitting construction of the 15-14120 mining face of Pingdingshan No. 8 Mine is carried out, and the effects of different single borehole diameters, different kerf widths and different kerf heights on the distribution area of surrounding coal fracture field and the degree of damage are studied quantitatively. These provide a theoretical basis for the reasonable determination of the slitting and drilling arrangement parameters at the engineering site.

The Finite Element Analysis of Dynamic Interaction of High-Speed Shinkansen, the Rail, and Bridge

1993 ◽  
Author(s):  
Makoto Tanabe ◽  
Hajime Wakui ◽  
Nobuyuki Matsumoto
Keyword(s):  
Finite Element ◽  
Dynamic Response ◽  
High Speed ◽  
Response Analysis ◽  
Element Formulation ◽  
Element Analysis ◽  
Finite Element Program ◽  
The Finite Element Analysis ◽  
Element Program ◽  
The Impact

Abstract A finite element formulation to solve the dynamic behavior of high-speed Shinkansen cars, rail, and bridge is given. A mechanical model to express the interaction between wheel and rail is described, in which the impact of the rail on the flange of wheel is also considered. The bridge is modeled by using various finite elements such as shell, beam, solid, spring, and mass. The equations of motions of bridge and Shinkansen cars are solved under the constitutive and constraint equations to express the interaction between rail and wheel. Numerical method based on a modal transformation to get the dynamic response effectively is discussed. A finite element program for the dynamic response analysis of Shinkansen cars, rail, and bridge at the high-speed running has been developed. Numerical examples are also demonstrated.

Predicting the Impact of Quenching on Mechanical Properties of Complex-Shaped Aluminum Alloy Parts

1995 ◽  
Vol 117 (2) ◽  
pp. 479-488 ◽  
Author(s):  
D. D. Hall ◽  
I. Mudawar
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Boundary Conditions ◽  
Finite Element Program ◽  
Part Geometry ◽  
Heat Treated ◽  
Element Program ◽  
Nozzle Configuration ◽  
The Impact

The mechanical properties of age-hardenable aluminum alloy extrusions are critically dependent on the rate at which the part is cooled (quenched) after the forming operation. The present study continues the development of an intelligent spray quenching system, which selects the optimal nozzle configuration based on part geometry and composition such that the magnitude and uniformity of hardness (or yield strength) is maximized while residual stresses are minimized. The quenching of a complex-shaped part with multiple, overlapping sprays was successfully modeled using spray heat transfer correlations as boundary conditions within a finite element program. The hardness distribution of the heat-treated part was accurately predicted using the quench factor technique; that is, the metallurgical transformations that occur within the part were linked to the cooling history predicted by the finite element program. This study represents the first successful attempt at systematically predicting the mechanical properties of a quenched metallic part from knowledge of only the spray boundary conditions.

Performance Evaluation of Spring for the Vehicle Suspension System Using the Nonlinear Finite Element Method

2014 ◽  
Vol 635-637 ◽  
pp. 594-597
Author(s):  
Byeong Soo Kim ◽  
Byung Young Moon ◽  
Sung Kwan Kim
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Composite Material ◽  
Suspension System ◽  
Nonlinear Finite Element ◽  
Nonlinear Finite Element Method ◽  
Air Spring ◽  
Rubber Sleeve ◽  
The Impact ◽  
Element Method

Air spring is used for the suspension system and it affects the vehicle stability and riding comfort by improving the impact-relief, braking, and cornering performance. Air Spring is comprised of the upper plate, lower plate, and rubber sleeve. Rubber sleeve is the composite material, which is made up of combination of rubber and Nylon, and the characteristics are changed according to the shape of rubber-sleeve, the angle of reinforcement cord. In this study, the distribution of internal stresses and the deformation of rubber composite material are analyzed through the nonlinear finite element method. The result showed that the internal maximum stresses and deformations about the changes of cord angle caused the more the Young's modulus decrease, the more maximum stress reduced.

Experimental Fretting-Wear Studies of Steam Generator Materials

1995 ◽  
Vol 117 (4) ◽  
pp. 312-320 ◽  
Author(s):  
N. J. Fisher ◽  
A. B. Chow ◽  
M. K. Weckwerth
Keyword(s):  
Steam Generator ◽  
Contact Force ◽  
Environmental Conditions ◽  
Analytical Techniques ◽  
Work Rate ◽  
Fretting Wear ◽  
Flow Induced Vibration ◽  
Dynamic Interactions ◽  
Support Materials ◽  
Wear Damage

Flow-induced vibration of steam generator tubes results in fretting-wear damage due to impacting and rubbing of the tubes against their supports. This damage can be predicted by computing tube response to flow-induced excitation forces using analytical techniques, and then relating this response to resultant wear damage using experimentally derived wear coefficients. Fretting-wear of steam generator materials has been studied experimentally at Chalk River Laboratories for two decades. Tests are conducted in machines that simulate steam generator environmental conditions and tube-to-support dynamic interactions. Different tube and support materials, tube-to-support clearances, and tube support geometries have been studied. The effect of environmental conditions, such as temperature, oxygen content, pH and chemistry control additive, have been investigated as well. Early studies showed that damage was related to contact force as long as other parameters, such as geometry and motion, were held constant. Later studies have shown that damage is related to a parameter called work-rate, which combines both contact force and sliding distance. Results of short and long-term fretting-wear tests for CANDU steam generator materials at realistic environmental conditions are presented. These results demonstrate that work-rate is an appropriate correlating parameter for impact-sliding interaction.

scholarly journals Finite Element Analysis of Structural Engineering Problems Using a Viscoplastic Model Incorporating Two Back Stresses

1995 ◽  
Vol 117 (2) ◽  
pp. 377-383 ◽  
Author(s):  
V. K. Arya ◽  
G. R. Halford
Keyword(s):  
Finite Element ◽  
Structural Engineering ◽  
Nonlinear Finite Element ◽  
Finite Element Analyses ◽  
Element Analysis ◽  
Finite Element Program ◽  
Viscoplastic Model ◽  
Engineering Problems ◽  
Element Program ◽  
Viscoplastic Models

The feasibility of a viscoplastic model incorporating two back stresses and a drag strength is investigated for performing nonlinear finite element analyses of structural engineering problems. The model has recently been put forth by Freed and Walker. The feasibility of the viscoplastic model is demonstrated for nonlinear structural analyses by implementing the model into a finite element program and performing nonlinear finite element analyses for several uniaxial and multiaxial problems. Good agreement is shown to exist between the results obtained using the finite element implementation and those obtained experimentally. The advantages of using advanced viscoplastic models for performing nonlinear finite element analyses of structural components are indicated.

Probabilistic Assessment of Fretting Wear in Steam Generator Tubes Under Flow Induced Vibrations

2003 ◽  
Author(s):  
Greg D. Morandin ◽  
Richard G. Sauve´
Keyword(s):  
Steam Generator ◽  
Degradation Mechanism ◽  
Probabilistic Methods ◽  
Fretting Wear ◽  
Nonlinear Flow ◽  
Impact Wear ◽  
Steam Generators ◽  
Flow Induced Vibration ◽  
Wear Damage ◽  
The Impact

Successful life management of steam generators requires an ongoing operational assessment plan to monitor and address all potential degradation mechanisms. A degradation mechanism of concern is tube fretting as a result of flow-induced vibration. Flow induced vibration predictive methods routinely used for design purposes are based on deterministic nonlinear structural analysis techniques. In previous work, the authors have proposed the application of probabilistic techniques to better understand and assess the risk associated with operating power generating stations that have aging re-circulating steam generators. Probabilistic methods are better suited to address the variability of the parameters in operating steam generators, e.g., flow regime, support clearances, manufacturing tolerances, tube to support interactions, and material properties. In this work, an application of a Monte Carlo simulation to predict the propensity for fretting wear in an operating re-circulation steam generator is described. Tube wear damage is evaluated under steady-state conditions using two wear damage correlation models based on the tube-to-support impact force time histories and work rates obtained from nonlinear flow induced vibration analyses. Review of the tube motion in the supports and the impact/sliding criterion shows that significant tube damage at the U-bend supports is a result of impact wear. The results of this work provide the upper bound predictions of wear damage in the steam generators. The EPRI wear correlations for sliding wear and impact wear indicate good agreement with the observed damage and, given the preponderance of wear sites subject to impact, should form the basis of future predictions.

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