Research Papers: Design and Analysis

Coupled Thermomechanical Analysis of Autofrettaged and Shrink-Fitted Compound Cylindrical Shells

[+] Author and Article Information
Ossama R. Abdelsalam

e-mail: ossama_ramy@yahoo.com

Ramin Sedaghati

Fellow ASME
e-mail: ramin.sedaghati@concordia.ca
Mechanical and Industrial Department,
Concordia University,
Montreal, Quebec H3G 1M8, Canada

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received February 14, 2013; final manuscript received June 27, 2013; published online October 23, 2013. Assoc. Editor: Albert E. Segall.

J. Pressure Vessel Technol 136(1), 011204 (Oct 23, 2013) (12 pages) Paper No: PVT-13-1035; doi: 10.1115/1.4025115 History: Received February 14, 2013; Revised June 27, 2013

In this study, different configurations of compound multilayer cylinders subjected to autofrettage and shrink-fit processes and under combined cyclic thermal and pressure loads have been investigated and their fatigue life has been evaluated and compared. Fully coupled thermo-elastic analysis is taken into consideration during the calculation of the temperature profile through the wall thickness. Finite element model for the compound two-layer cylinder has been constructed and then validated with previous work in the literature and experimental work. In the experimental work, the temperature has been measured at different locations through the thickness of a two-layer shrink-fitted cylinder (SFC), subjected to internal quasi-static and dynamic thermal loads. Besides, the hoop strain at the outer surface of the cylinder has been measured for the same thermal loads. Using the developed finite element model, the hoop stress distributions through the thickness of different configurations of the compound cylinder have been calculated under different loading conditions, including internal static pressure, internal cyclic thermal loads, and combination of these loads. The mechanical fatigue life has been calculated using ASME codes due to the internal cyclic pressure. Moreover, the stress intensity factor (SIF) has been calculated for these configurations under cyclic thermal loads or cyclic thermomechanical loads, considering thermal accumulation. The stress intensity factors for different configurations have been compared with the critical SIF which is the fracture toughness of the material. The number of stress cycles required until the SIF reaches the critical SIF has been considered as the fatigue life for each configuration. It has been found that for the cases of cyclic thermal loads and combined cyclic pressure and thermal loads, the shrink-fitting of two layers followed by the autofrettage of the assembly is the best configuration to enhance the fatigue life of the two-layer cylinder.

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Fig. 1

Physical model and coordinate system of a multilayer long cylinder

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Fig. 2

Temperature distribution through thickness due to cyclic thermal pulses

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Fig. 7

Temperature profile with time at the three different locations in the wall thickness-quasi-static thermal load

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Fig. 8

Temperature distribution through the thickness at different measuring times-quasi-static thermal load

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Fig. 9

Temperature–time profiles at three different depths comparing the FEM results with the experimental data-dynamic thermal load

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Fig. 10

Temperature distribution through thickness at different measuring times-dynamic thermal load

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Fig. 3

Shrink-fitting process with the help of hydraulic axial press

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Fig. 4

On the left, the thermocouples fixed at different depths. On the right, the strain gauge fixed at the outer surface.

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Fig. 5

Test rig contents: strain meter, control electric valve, test specimen, and thermocouples

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Fig. 6

The time-dependent variation of the inner surface temperature

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Fig. 11

Residual hoop stresses for different configurations through the wall thickness

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Fig. 14

Hoop stress distribution for the different configurations when subjected to static inner pressure of 250 MPa

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Fig. 15

Hoop stress distribution for the different configurations after 100 thermal and pressure pulses

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Fig. 12

The hoop stress distribution through the thickness after different cyclic thermal pulses for a single layer thick-walled cylinder

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Fig. 13

Hoop stress distribution for the different configurations after 150 thermal pulses

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Fig. 16

Combined pressure and thermal pulses and the points of calculation

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Fig. 17

Semi-elliptical crack in a single layer [18]

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Fig. 18

SIF versus number of pulses for different configurations when subjected to cyclic thermal pulses

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Fig. 19

SIF versus number of pulses for different configurations when subjected to cyclic thermomechanical pulses




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