Modeling Hydraulically Expanded Tube-to-Tubesheet Joint Based on General Stress-Strain Curves of Tube and Tubesheet Materials

2011 ◽  
Vol 133 (3) ◽  
Author(s):  
Xiaoping Huang ◽  
Tian Xie
Keyword(s):  
Strain Hardening ◽  
Contact Pressure ◽  
Present Model ◽  
Design Parameters ◽  
Linear Strain ◽  
Stress Strain ◽  
Hardening Model ◽  
Expansion Pressure ◽  
Special Cases ◽  
Analytic Expressions

The strength of tube-to-tubesheet joints is crucial for the joint integrity and reliability of the tubular heat exchangers. The joint strength measured by residual contact pressure is affected by several design parameters, such as the yield strength and strain hardening of the tube and tubesheet materials, initial radial clearance between the tube and tubesheet hole, and the magnitude of the expansion. It is very important to determine the expansion pressure and the residual contact pressure in designing and manufacturing tube-to-tubesheet joints by the hydraulic expansion process. In this paper, a general strain-hardening material model and analytic expressions for calculating the expansion pressure and the residual contact pressure, considering the effect of the initial clearance and the material strain hardening, have been derived. The results predicted by the present model have been compared with the results predicted by elastic perfectly plastic model, linear strain-hardening model, and the nonlinear finite element analysis results. The comparison results show that the present analytic expressions can model the effects of strain-hardening of the materials and the clearance well. The models, such as elastic-perfect model, linear strain-hardening model, and power strain-hardening model, are the special cases of the present model. The parameters needed in the present model are determined by curve fitting of the actual tensile stress-strain data of tube and tubesheet materials, respectively.

Determination of Expanding Pressure of Hydraulically Expanded Tube-to-Tubesheet Joint

2010 ◽  
Vol 97-101 ◽  
pp. 2898-2902 ◽  
Author(s):  
Xie Tian ◽  
Xiao Ping Huang ◽  
Zhi Yong Fu
Keyword(s):  
Strain Hardening ◽  
Contact Pressure ◽  
Material Model ◽  
Linear Strain ◽  
Element Analysis ◽  
Hardening Material ◽  
Expansion Pressure ◽  
General Strain ◽  
Special Case

It is very important to determine the expansion pressure or residual contact pressure of tube-to-tubesheet joint. The expansion pressure and the residual contact pressure are affected by the geometry, material mechanical properties of the tube and tubesheet. In the basic theory of calculating the residual contact pressure of tube-to-tubesheet joints, the elastic-perfectly material is assumed. Because of the strain-hardening of the materials, linear strain-hardening or power strain-hardening were adopted in some analyzing models of the hydraulically expanded tube-to-tubesheet joint. In this paper, a general strain-hardening material model is adopted and an analytical model is proposed and validated by finite element analysis results. The elastic-perfectly model, linear strain-hardening model or power strain-hardening can be the special case of the present model.

Combined Effects of Tube Projection, Initial Tube-Tubesheet Clearance, and Tube Material Strain Hardening on Rolled Joint Strength

2009 ◽  
Vol 131 (5) ◽  
Author(s):  
N. Merah ◽  
A. Al-Aboodi ◽  
A. N. Shuaib ◽  
Y. Al-Nassar ◽  
S. S. Al-Anizi
Keyword(s):  
Finite Element ◽  
Strain Hardening ◽  
Contact Pressure ◽  
Joint Strength ◽  
Element Model ◽  
Design Parameters ◽  
Radial Clearance ◽  
Tube Material ◽  
Element Analysis ◽  
Interfacial Pressure

The tube-to-tubesheet joint strength is measured in terms of interfacial pressure between the tube’s outer surface and tubesheet bore. The strength of a rolled joint is influenced by several design parameters, including the type of tube and tubesheet materials, initial tube projection, and the initial radial clearance between the tube and tubesheet, among other factors. This paper uses finite element analysis (FEA) to evaluate the effect of several parameters on the strength of rolled joints having large overtolerances, a situation that applies to used equipment. An axisymmetric finite element model based on the sleeve diameter and rigid tube expanding roller concepts was used to analyze the effects of tube projection, initial tube-tubesheet clearance, and tube material strain-hardening property on the deformation behavior of the rolled tube and on the strength of the tube-tubesheet joint. The FEA results show that for zero tube projection (flush) the initial clearance effect is dependent on the strain-hardening capability of the tube material. For low strain-hardening tube material the interfacial pressure remains constant well above the Tubular Exchanger Manufacturer’s Association maximum overtolerance. A drastic reduction in joint strength is observed at high values of radial clearances. The cut-off clearance (clearance at which the interfacial pressure starts to drop) is found to vary linearly with the tube material hardening level, and the contact stress increases slightly for moderate strain-hardening tube materials but shows lower cut-off clearance levels. Furthermore, with flush tubes the maximum contact pressure occurs close to the secondary face (at the end of rolling) while for joints with initial tube projection the contact pressure shows two maxima occurring near the primary and the secondary faces. This is attributed to the presence of two elbows in tube deformation near the primary and secondary faces. The average interfacial pressure increased with increasing projection length for all clearances. Tube material strain hardening enhances the interfacial pressure in a similar fashion for all initial tube projection lengths considered in the analysis.

A full-range stress-strain model for metallic materials depicting non-linear strain-hardening behavior

2020 ◽  
pp. 030932472095779
Author(s):  
Digendranath Swain ◽  
S Karthigai Selvan ◽  
Binu P Thomas ◽  
Ahmedul K Asraff ◽  
Jeby Philip
Keyword(s):  
Constitutive Model ◽  
Strain Hardening ◽  
Image Correlation ◽  
Linear Strain ◽  
Stress Strain ◽  
Material Parameters ◽  
Hardening Behavior ◽  
Non Linear ◽  
Strain Hardening Behavior ◽  
Strain Model

Ramberg-Osgood (R-O) type stress-strain models are commonly employed during elasto-plastic analysis of metals. Recently, 2-stage and 3-stage R-O variant models have been proposed to replicate stress-strain behavior under large plastic deformation. The complexity of these models increases with the addition of each stage. Moreover, these models have considered deformation till necking only. In this paper, a simplistic multi-stage constitutive model is proposed to capture the strain-hardening non-linearity shown by metals including its post necking behavior. The constitutive parameters of the proposed stress-strain model can be determined using only elastic modulus and yield strength. 3-D digital image correlation was used as an experimental tool for measuring full-field strains on the specimens, which were subsequently utilized to obtain the material parameters. Our constitutive model is demonstrated with an aerospace-grade stainless steel AISI 321 wherein deformation response averaged over the gauge length (GL) and at a local necking zone are compared. The resulting averaged and local material parameters obtained from the proposed model provide interesting insights into the pre and post necking deformation behavior. Our constitutive model would be useful for characterizing highly ductile metals which may or may not depict non-linear strain hardening behavior including their post necking deformations.

Modeling the Effects of Initial Tube-Tubesheet Clearance, Wall Reduction and Material Strain Hardening on Rolled Joint Strength

2008 ◽  
Vol 130 (4) ◽  
Author(s):  
A. Al-Aboodi ◽  
N. Merah ◽  
A. R. Shuaib ◽  
Y. Al-Nassar ◽  
S. S. Al-Anizi
Keyword(s):  
Finite Element ◽  
Strain Hardening ◽  
Contact Pressure ◽  
Joint Strength ◽  
Design Parameters ◽  
Radial Clearance ◽  
Residual Pressure ◽  
Tube Material ◽  
Noticeable Effect ◽  
Interfacial Pressure

The tube-to-tubesheet joint strength is measured in terms of residual contact pressure between the tube’s outer surface and tubesheet hole surfaces. The joint integrity is affected by several design parameters, including the type of tube and tubesheet materials, the level of expansion, and the initial radial clearance between the tube and tubesheet. In the present work, an axisymmetric finite element model based on the sleeve diameter and rigid roller concepts is developed. The model has been used to evaluate the combined effects of clearance, wall reduction level, and strain hardening of tube and tubesheet materials on the interfacial pressure between tube and tubesheet. The finite element results show that the initial clearance effect is dependent on the strain hardening capability of the tube material. For low strain hardening tube materials, the interfacial pressure remains almost constant well above the Tubular Exchanger Manufacturing Association maximum radial over tolerance of 0.0254mm(0.001in.). These results are validated by the experimental data developed during the research program. As expected, a drastic reduction in joint strength is observed at high values of radial clearances. The cutoff clearance (clearance at which the interfacial pressure starts to drop) is found to vary linearly with tube material hardening level. The residual pressure is found to increase slightly for moderate strain hardening tube materials but shows lower cutoff clearances. Wall reductions ranging from 1% to 12% were utilized in calculating the contact pressure as a function of radial clearance. The results show that for low strain hardening materials the optimum value of residual contact stress is obtained for the industry recommended value of 5%. Finally, because of the absence of plastic deformation in the ligament, the level of tubesheet material strain hardening does not have any noticeable effect on the joint strength.

scholarly journals Cyclic Stress-strain Hardening Model of AC4C-T6 Alloy at Cryogenic Temperature

2009 ◽  
Vol 46 (5) ◽  
pp. 498-509 ◽  
Author(s):  
Jae-Beom Lee ◽  
Kyung-Su Kim ◽  
Jang-Hyun Lee ◽  
Mi-Ji Yoo ◽  
Joon-Mo Choung
Keyword(s):  
Strain Hardening ◽  
Cryogenic Temperature ◽  
Cyclic Stress ◽  
Stress Strain ◽  
Hardening Model

Effect of Bauschinger Effect and Yield Criterion on Residual Stress Distribution of Autofrettaged Tube

2005 ◽  
Vol 128 (2) ◽  
pp. 212-216 ◽  
Author(s):  
X. P Huang ◽  
W. C. Cui
Keyword(s):  
Experimental Data ◽  
Residual Stress ◽  
Stress Distribution ◽  
Strain Hardening ◽  
Bauschinger Effect ◽  
Present Model ◽  
Yield Criterion ◽  
Residual Stress Distribution ◽  
Hardening Model ◽  
End Conditions

Many analytical and numerical solutions for determining the residual stress distribution in autofrettaged tube have been reported. The significance of the choice of yield criterion, the Bauschinger effect, strain hardening, and the end conditions on the predicted residual stress distribution has been discussed by many authors. There are some different autofrettage models based on different simplified material strain-hardening behaviors, such as a linear strain-hardening model, power strain-hardening model, etc. Those models give more accurate predictions than that of elastic–perfectly plastic model, and each of them suits different strain-hardening materials. In this paper, an autofrettage model considering the material strain-hardening relationship and the Bauschinger effect, based on the actual tensile-compressive stress-strain curve of material, plane-strain, and modified yield criterion, has been proposed. The predicted residual stress distributions of autofrettaged tubes from the present model are compared to the numerical results and the experimental data. The predicted residual stresses are in good agreement with the experimental data and numerical predictions. The effect of Bauschinger effect and yield criterion on residual stress is discussed based on the present model. To predict residual stress distribution accurately, it is necessary to properly model yield criterion, Bauschinger effect, and appropriate end conditions.

FEA of the Effects of Initial Tube-Tubesheet Clearance, Wall Reduction and Material Strain Hardening on Rolled Joint Strength

2006 ◽  
Author(s):  
A. Al-Aboodi ◽  
N. Merah ◽  
A. R. Shuaib ◽  
Y. Al-Nassar ◽  
S. S. Al-Anizi
Keyword(s):  
Strain Hardening ◽  
Contact Pressure ◽  
Joint Strength ◽  
Element Model ◽  
Design Parameters ◽  
Radial Clearance ◽  
Residual Pressure ◽  
Tube Material ◽  
Noticeable Effect ◽  
Interfacial Pressure

The tube-to-tubesheet joint strength is measured in terms of residual contact pressure between the tube’s outer surface and tubesheet hole surfaces. The joint integrity is affected by several design parameters, including the type of tube and-tubesheet materials, level of expansion and the initial radial clearance between the tube and tubesheet. In the present work, an axisymmetric finite element model based on the sleeve diameter and rigid roller concepts is developed. The model has been used to evaluate the combined effects of clearance, wall reduction level and the-strain hardening of tube and tubesheet materials on the interfacial pressure between tube and tubesheet. The FE results show that the initial clearance effect is dependent on the strain hardening capability of the tube material. For low strain hardening tube material the interfacial pressure remains almost constant well above the TEMA (Tubular Exchanger Manufacturing Association) maximum radial over tolerance of 0.0254 mm. These results are validated by the experimental data developed during the research program. As expected, a drastic reduction in joint strength is observed at high values of radial clearances. The cut-off clearance (clearance at which the interfacial pressure starts to drop) is found to vary linearly with the level tube material hardening level. The residual pressure is found to increase slightly for moderate strain hardening tube materials but shows lower cut-off clearances. Wall reductions ranging from 1% to 10% were utilized in calculating the contact pressure as a function of radial clearance. The results show that for low strain hardening materials the optimum value of residual contact stress is obtained for the industry recommended value of 5%. Finally, because of the absence plastic deformation in the ligament, the level of tubesheet material strain hardening does not have any noticeable effect to the joint strength.

Study on Constitutive Mode of Three Typical Rocks Based on Triaxial Compression Test

2012 ◽  
Vol 170-173 ◽  
pp. 322-326
Author(s):  
Kui Chen ◽  
Ren Hua Yang ◽  
Tao Xu ◽  
Ya Jing Qi
Keyword(s):  
Residual Strength ◽  
Triaxial Compression ◽  
Confining Pressure ◽  
Digital Design ◽  
Peak Strength ◽  
Design Parameters ◽  
Stress Strain ◽  
Red Sandstone ◽  
Constitutive Mode ◽  
Shield Machine

In order to study the relationship between the design parameters of the shield machine and the strength of rock, the behaviours of rocks under the conventional triaxial compression, the complete stress-strain curves under different confining pressures of three typical rocks, i.e. granite, limestone and red sandstone, were taken out for analysis. From the curves, the values of elastic modulus E and Poisson's ratio μ were gained and the relationships between the following parameters were figured out, which are peak strength versus confining pressure, residual strength versus confining pressure, strain at peak strength versus confining pressure, and strain at residual strength versus confining pressure. According to the values and relationships, the complete stress-strain curves were divided into three parts. For each part, a constitutive equation was established by using the strain softening trilinear elastic-brittle-plastic constitutive model, and all the related parameters in the constitutive equations were also presented, which provide a theoretical foundation for the digital design of the cutter head and cutters of Shield machine.

Development of a Methodology for Model Testing of Utor Welded Joints of a Vertical Cylindrical Tank

2021 ◽  
pp. 21-27
Author(s):  
D.A. Neganov ◽  
◽  
A.E. Zorin ◽  
O.I. Kolesnikov ◽  
G.V. Nesterov ◽  
...  
Keyword(s):  
Welded Joints ◽  
Strain State ◽  
Welded Joint ◽  
Design Parameters ◽  
Cylindrical Tank ◽  
Stress Strain ◽  
The Real ◽  
Stress Strain State ◽  
Hydraulic Machines ◽  
Wide Range

The methodology of laboratory modeling of the loading of utor welded joint of the tank is presented. The methodology is based on testing of the special design sample. It allows under uniaxial tension on the typical servo-hydraulic machines to reproduce in the zone of a utor welded joint the combined action of bending and shear forces, similar to that which occurs during the operation of a vertical cylindrical tank. To assess the distribution of the stress-strain state in the proposed design of the sample under its loading, the finite element modeling was performed in the ANSYS software package. It showed the fundamental correspondence of the stress distribution in the zone of the utor node in the sample and in the real tank. The experimental studies consisted in carrying out tests for the durability of a series of 16 samples loaded with the maximum force in the cycle, causing the calculated stresses in the zone of the welded utor node in the range of 100–200 % from the maximum permissible ones. The obtained results showed that the maximum loaded zone, where the destruction of the samples occurred, is the near-seam zone of the utor welded joint on the inside of the tank. This corresponds to the statistics of the real tank failures. It is established that the developed methodology ensures the possibility of carrying out correct resource tests of the tank utor welded joints. It is also possible to vary the stress-strain state scheme within a wide range in the area of the utor welded joint by changing the design parameters of the test sample. In compliance with the regulated welding technologies and the absence of unacceptable defects in the welded joint, the utor node has a high resource, which significantly exceeding 50 years of the tank operation.

scholarly journals Thermodynamic and Elastic Properties of Interstitial Alloy FeC with BCC Structure at Zero Pressure

2018 ◽  
Vol 2018 ◽  
pp. 1-8 ◽  
Author(s):  
Bui Duc Tinh ◽  
Nguyen Quang Hoc ◽  
Dinh Quang Vinh ◽  
Tran Dinh Cuong ◽  
Nguyen Duc Hien
Keyword(s):  
Nearest Neighbor ◽  
Young Modulus ◽  
Thermodynamic Quantities ◽  
Atom Concentration ◽  
Main Metal ◽  
Special Cases ◽  
Analytic Expressions ◽  
Rigidity Modulus ◽  
Bcc Structure ◽  
The Mean

The analytic expressions for the thermodynamic and elastic quantities such as the mean nearest neighbor distance, the free energy, the isothermal compressibility, the thermal expansion coefficient, the heat capacities at constant volume and at constant pressure, the Young modulus, the bulk modulus, the rigidity modulus, and the elastic constants of binary interstitial alloy with body-centered cubic (BCC) structure, and the small concentration of interstitial atoms (below 5%) are derived by the statistical moment method. The theoretical results are applied to interstitial alloy FeC in the interval of temperature from 100 to 1000 K and in the interval of interstitial atom concentration from 0 to 5%. In special cases, we obtain the thermodynamic quantities of main metal Fe with BCC structure. Our calculated results for some thermodynamic and elastic quantities of main metal Fe and alloy FeC are compared with experiments.

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