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Research Papers: Design and Analysis

Residual Stresses in Roller Expanded Tube-Tubesheet Joints With Large Initial Clearance and Grooves

[+] Author and Article Information
A. N. Shuaib

Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabiaarshuaib@kfupm.edu.sa

O. M. Duffuaa, N. Merah, Y. Al-Nassar

Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabia

J. Pressure Vessel Technol 133(5), 051211 (Jul 20, 2011) (7 pages) doi:10.1115/1.4003465 History: Received May 07, 2010; Revised December 11, 2010; Published July 20, 2011; Online July 20, 2011

Heat exchanger tube rolling introduces tensile residual stresses in the expanded part of the tube and the transition zone between the expanded and unexpanded regions of the tube. These tensile residual stresses accelerate fatigue crack initiation and enhance small crack propagation and may cause stress corrosion cracking of the tube if it is exposed to a corrosive environment. In this paper, an axisymmetric finite element model has been used to evaluate the effect of large initial tube-tubesheet radial clearance and to evaluate the effects of grooves machined in the tubesheet hole on the distributions and magnitudes of the radial deformation of tube walls and the residual stresses along the expanded length of the tube and in the transition zone. The results have revealed the presence of tensile and compressive residual axial and hoop stresses in the inner and outer surfaces of the tubes with various degrees of severity.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

(a) Equivalent sleeve joint model and (b) FE mesh for the grooved joint

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Figure 2

Radial displacement of the inner surface (Uri) and outer surface (Uro) along the expanded length of the tube rolled in (a) joints without groove and (b) joints with grooves

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Figure 3

Effects of clearance, (a) coefficient of friction (μ), and (b) grooves on the average residual contact stress of the rolled joints

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Figure 4

Effect of clearance on the (a) residual axial stress and (b) residual hoop stress of the inner surface of tube in the joint without groove

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Figure 5

Effect of clearance on the (a) residual axial stress and (b) residual hoop stress of the outer surface of tube in the joint without groove

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Figure 6

Distributions, at three levels of clearance, of the (a) residual axial stress and (b) residual hoop stress of the inner surface of the tube rolled in the joint with two grooves

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Figure 7

Distributions, at three levels of clearance, of the (a) residual axial stress and (b) residual hoop stress of the outer surface of the tube rolled in the joint with two grooves

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