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Research Papers: Design and Analysis

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

[+] Author and Article Information
Xiaoping Huang, Tian Xie

State Key Laboratory of Ocean Engineering, Shanghai Jiao Tong University, Shanghai 200240, China

J. Pressure Vessel Technol 133(3), 031205 (Apr 01, 2011) (9 pages) doi:10.1115/1.4002259 History: Received December 30, 2009; Revised June 29, 2010; Published April 01, 2011; Online April 01, 2011

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.

Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Geometry parameters of the simplified joint

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Figure 2

Illustration of the expansion pressure versus the radial displacement in tube-to-tubesheet expansion process

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Figure 3

General material stress-strain curves of tube and tubesheet

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Figure 4

Geometry parameters of tube before tube contact with the tubesheet hole

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Figure 5

Analysis model after tube contacts the tubesheet hole

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Figure 6

Stress-strain curve of SA-556M

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Figure 7

Stress-strain curve of SA-350LF2

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Figure 8

Stress-strain curve of 10#

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Figure 9

Stress-strain curve of 16Mn

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Figure 10

Meshed plane strain/stress model

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Figure 11

Residual contact pressure distribution on the contact surface

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Figure 12

Comparison of predicted results with FEA results case 1

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Figure 13

Comparison of predicted results with FEA results case 2

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Figure 14

The effect of initial clearance and material strain hardening on residual contact pressure

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Figure 15

The effect of initial clearance on specified expansion pressure

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