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Research Papers: Design and Analysis

A Finite Element Method Study of Combined Hydraulic and Thermal Autofrettage Process

[+] Author and Article Information
Rajkumar Shufen

Department of Mechanical Engineering,
Indian Institute of Technology Guwahati,
Guwahati 781 039, India

Uday S. Dixit

Department of Mechanical Engineering,
Indian Institute of Technology Guwahati,
Guwahati 781 039, India
e-mail: uday@iitg.ac.in

1Corresponding author.

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received October 9, 2016; final manuscript received February 14, 2017; published online April 21, 2017. Assoc. Editor: Yun-Jae Kim.

J. Pressure Vessel Technol 139(4), 041204 (Apr 21, 2017) (9 pages) Paper No: PVT-16-1187; doi: 10.1115/1.4036143 History: Received October 09, 2016; Revised February 14, 2017

Autofrettage is a metal working process of inducing compressive residual stresses in the vicinity of the inner surface of a thick-walled cylindrical or spherical pressure vessel for increasing its pressure capacity, fatigue life, and stress-corrosion resistance. The hydraulic autofrettage is a class of autofrettage processes, in which the vessel is pressurized using high hydraulic pressure to cause the partial plastic deformation followed by unloading. Despite its popularity, the requirement of high pressure makes this process costly. On the other hand, the thermal autofrettage is a simple method, in which the residual stresses are set up by first maintaining a temperature difference across the thickness of the vessel and then cooling it to uniform temperature. However, the increase in the pressure carrying capacity in thermal autofrettage process is lesser than that in the hydraulic autofrettage. In the present work, a combined hydraulic and thermal autofrettage process of a thick-walled cylinder is studied using finite element method package ABAQUS® for aluminum and SS304 steel. The strain-hardening and Bauschinger effects are considered and found to play significant roles. The results show that the combined autofrettage can achieve desired increase in the pressure capacity of thick-walled cylinders with relatively small autofrettage pressure. For example, in a SS304 cylinder of wall-thickness ratio of 3, an autofrettage pressure of 150 MPa enhances the pressure capacity by 41%, but the same pressure with a 36 °C higher inner surface temperature than outer surface temperature can enhance the pressure capacity by 60%.

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Figures

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Fig. 1

Schematic of part in ABAQUS® along with boundary conditions

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Fig. 2

A typical FEM mesh for (a) SS304 and (b) aluminum cylinders

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Fig. 3

Elastoplastic stress distributions for hydraulic autofrettage of 4333 M4 based on FEM, theoretical, and experimental results (b/a = 2.06) in the middle of 5 mm long cylinder

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Fig. 4

Comparison of (a) radial residual stress distribution, (b) hoop residual stress distribution, and (c) axial residual stress distribution for hydraulic autofrettage of M4 4333 based on FEM, analytical, and experimental results (b/a = 2.06) at the middle of 5 mm long cylinder

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Fig. 5

Comparison of elastoplastic stress distribution for the thermal autofrettage of SS304 based on theoretical and FEM models (b/a = 2.5)

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Fig. 6

Comparison of (a) radial residual stress distribution, (b) hoop residual stress, and (c) axial residual stress distribution for thermal autofrettage of SS304 based on FEM, analytical, and experimental results (b/a = 2.5)

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Fig. 7

Elastoplastic stress distribution in combined autofrettage of SS304 cylinder using pressure 105 MPa and temperature difference 65 °C (b/a = 3)

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Fig. 8

Residual stress distribution in combined autofrettage of SS304 cylinder using pressure 105 MPa and temperature difference 65 °C (b/a = 3)

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Fig. 9

Elastoplastic stress distribution in combined autofrettage of aluminum cylinder using pressure 21 MPa and temperature difference 35 °C (b/a = 2)

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Fig. 10

Residual stress distribution in combined autofrettage of aluminum cylinder using pressure 21 MPa and temperature difference 35 °C (b/a = 2)

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Fig. 11

Variation of the increase in pressure carrying capacity with autofrettage pressure and temperature difference in combined autofrettage of SS304 cylinder for (a) nonhardening and (b) hardening material

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Fig. 12

Variation of the increase in pressure carrying capacity with autofrettage pressure and temperature difference in combined autofrettage of aluminum cylinder for (a) nonhardening and (b) hardening material

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