0
Research Papers: Materials and Fabrication

Analysis of Residual Stress in the Rotational Autofrettage of Thick-Walled Disks

[+] Author and Article Information
S. M. Kamal

Department of Mechanical Engineering,
Tezpur University,
Napaam, Tezpur 784028, Assam, India
e-mail: smkmech@tezu.ernet.in

1Corresponding author.

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received May 10, 2017; final manuscript received August 27, 2018; published online November 12, 2018. Assoc. Editor: Yun-Jae Kim.

J. Pressure Vessel Technol 140(6), 061402 (Nov 12, 2018) (10 pages) Paper No: PVT-17-1085; doi: 10.1115/1.4041339 History: Received May 10, 2017; Revised August 27, 2018

Autofrettage is a means of generating compressive residual stresses at the inner side of a thick-walled cylinder or hollow disk by causing nonhomogeneous plastic deformation of the material at the inner side. The presence of residual compressive stresses at the inner region of the cylinder/disk enhance the pressure withstanding capacity, fatigue life and the resistance to stress corrosion cracking of the component. Despite the hydraulic and swage autofrettage are the widely practiced processes in industries, there are certain disadvantages associated with these processes. In view of this, in the recent years, researchers have proposed new methods of achieving autofrettage. Rotational autofrettage is such a recently proposed autofrettage method for achieving the beneficial compressive residual stresses in the cylinders. In the present work, the rotational autofrettage is studied for a thick-walled hollow circular disk. A theoretical analysis of the residual stresses produced in the disk after unloading are obtained assuming plane stress condition, Tresca yield criterion and its associated flow rule. The analysis takes into account the effect of strain hardening during plastic deformation. Further, the effect of residual stresses in the typical SS304 and aluminum disk is studied by subjecting them into three different types of loads viz., internal pressure, radial temperature difference, and rotational speed individually. A three-dimensional (3D) finite element method (FEM) validation of the theoretical stresses during rotational autofrettage of a disk is also presented.

FIGURES IN THIS ARTICLE
<>
Copyright © 2018 by ASME
Your Session has timed out. Please sign back in to continue.

References

Jacob, L. , 1907, “ La Résistance etL'équilibreElastique Des Tubes Frettés,” Mémoire de L'artillerie Navale, 1(5), pp. 43–155. (in French)
Davidson, T. E. , Barton, C. S. , Reiner, A. N. , and Kendall, D. P. , 1962, “ New Approach to the Autofrettage of High-Strength Cylinders,” Exp. Mech., 2(2), pp. 33–40. [CrossRef]
Mote, J. D. , Ching, L. K. W. , Knight, R. E. , Fay, R. J. , and Kaplan, M. A. , 1971, “ Explosive Autofrettage of Cannon Barrels,” Army Materials and Mechanics Research Center, Watertown, MA, Report No. AMMRC CR 70-25. http://www.dtic.mil/dtic/tr/fulltext/u2/718867.pdf
Kamal, S. M. , and Dixit, U. S. , 2015, “ Feasibility Study of Thermal Autofrettage of Thick-Walled Cylinders,” ASME J. Pressure Vessel Technol., 137(6), p. 061207. [CrossRef]
Turner, L. B. , 1910, “ The Stresses in a Thick Hollow Cylinder Subjected to Internal Pressure,” Trans. Cambridge Philos. Soc., 21(14), pp. 377–396.
Thomas, D. G. B. , 1953, “ The Autofrettage of Thick Tubes With Free Ends,” J. Mech. Phys. Solids, 1(2), pp. 124–133. [CrossRef]
Hill, R. , Lee, E. H. , and Tupper, S. J. , 1957, “ The Theory of Combined Plastic and Elastic Deformation With Particular Reference to a Thick Tube Under Internal Pressure,” Proc. R. Soc. London, Ser. A, Math. Phys. Sci., 191(1026), pp. 278–303. https://www.jstor.org/stable/98038
Rees, D. W. A. , 1990, “ Autofrettage Theory and Fatigue Life of Open-Ended Cylinders,” J. Strain Anal. Eng. Des., 25(2), pp. 109–121. [CrossRef]
Gao, X. L. , 1992, “ An Exact Elasto-Plastic Solution for an Open-Ended Thick-Walled Cylinder of a Strain-Hardening Material,” Int. J. Pressure Vessel Piping, 52(1), pp. 129–44. [CrossRef]
Parker, A. P. , Underwood, J. H. , and Kendall, D. P. , 1999, “ Bauschinger Effect Design Procedures for Autofrettaged Tubes Including Material Removal and Sachs' Method,” ASME J. Pressure Vessel Technol., 121(4), pp. 430–437. [CrossRef]
Huang, X. P. , and Moan, T. , 2009, “ Residual Stress in an Autofrettaged Tube Taking Bauschinger Effect as a Function of the Prior Plastic Strain,” ASME J. Pressure Vessel Technol., 131(2), p. 021207. [CrossRef]
Alegre, J. M. , Bravo, P. , and Preciado, M. , 2006, “ Design of an Autofrettaged High Pressure Vessel Considering the Bauschinger Effect,” Proc. Inst. Mech. Eng., Part E: J. Process Mech. Eng., 220(1), pp. 7–16. [CrossRef]
Jahed, H. , and Dubey, R. N. , 1997, “ An Axisymmetric Method of Elastic-Plastic Analysis Capable of Predicting Residual Stress Field,” ASME J. Pressure Vessel Technol., 119(3), pp. 264–273. [CrossRef]
Alexandrov, S. , Jeong, W. , and Chung, K. , 2016, “ Descriptions of Reversed Yielding in Internally Pressurized Tubes,” ASME J. Pressure Vessel Technol., 138(1), p. 011204. [CrossRef]
Majzoobi, G. H. , Farrahi, G. H. , and Mahmoudi, A. H. , 2003, “ A Finite Element Simulation and an Experimental Study of Autofrettage for Strain Hardened Thick-Walled Cylinders,” Mater. Sci. Eng. A, 359(1–2), pp. 326–331. [CrossRef]
Kihiu, J. M. , Mutuli, S. M. , and Rading, G. O. , 2003, “ Stress Characterization of Autofrettaged Thick-Walled Cylinders,” Int. J. Mech. Eng. Educ., 31(4), pp. 370–389. [CrossRef]
Gibson, M. C. , Hameed, A. , Parker, A. P. , and Hetherington, J. G. , 2006, “ A Comparison of Methods for Predicting Residual Stresses in Strain-Hardening, Autofrettaged Thick Cylinders, Including the Bauschinger Effect,” ASME J. Pressure Vessel Technol., 128(2), pp. 217–222. [CrossRef]
Parker, A. P. , Gibson, M. C. , Hameed, A. , and Troiano, E. , 2012, “ Material Modeling for Autofrettage Stress Analysis Including “Single Effective Material,” ASME J. Pressure Vessel Technol., 134(4), p. 041004. [CrossRef]
O'Hara, G. P. , 1992, “ Analysis of the Swage Autofrettage Process,” U. S. Army Armament Research Development and Engineering Center, Benét Laboratories, Watervliet, NY, Technical Report No. ARCCB-TR-92016.
Bihamta, R. , Movahhedy, M. R. , and Mashreghi, A. R. , 2007, “ A Numerical Study of Swage Autofrettage of Thick-Walled Tubes,” Mater. Des., 28 (3), pp. 804–815. [CrossRef]
Barbáchano, H. , Alegre, J. M. , and Cuesta, I. I. , 2011, “ FEM Simulation of the Swage Tube Forming (STF) in Cylinders Subjected to Internal Pressure,” An. Mec. Fract., 28(2), pp. 481–486.
Dewangan, M. K. , and Panigrahi, S. K. , 2015, “ Residual Stress Analysis of Swage Autofrettaged Gun Barrel Via Finite Element Method,” J. Mech. Sci. Technol., 29(7), pp. 2933–2938. [CrossRef]
Chen, P. C. T. , 1988, “ A Simple Analysis of the Swage Autofrettage Process,” U.S. Army Armament Research, Development and Engineering Center, Close Combat Armaments Center, Benét Laboratories, Watervliet, NY, Technical Report No. ARCCB-TR-88030.
Rees, D. W. A. , 2011, “ A Theory for Swaging of Discs and Lugs,” Meccanica, 46(6), pp. 1213–1237. [CrossRef]
Ren-rui, Z. , Chun-da, T. , and Guo-zhen, Z. , 1999, “ Elasto-Plastical Dynamic Analysis of Explosive Autofrettage,” Southwest Pet. Univ. (Natural Sci.), 21(4), pp. 82–85. http://en.cnki.com.cn/Article_en/CJFDTOTAL-XNSY199904022.htm
Clark, G. , 1984, “ Fatigue Crack Growth Through Residual Stress Fields-Theoretical and Experimental Studies on Thick-Walled Cylinders,” Theor. Appl. Fract. Mech., 2(2), pp. 111–125.
Stacey, A. , MacGillivary, H. J. , Webster, G. A. , Webster, P. J. , and Ziebeck, K. R. A. , 1985, “ Measurement of Residual Stresses by Neutron Diffraction,” J. Strain Anal. Eng. Des., 20(2), pp. 93–100. [CrossRef]
George, D. , and Smith, D. J. , 2000, “ The Application of the Deep Hole Technique for Measuring Residual Stresses in an Autofrettaged Tube,” Am Soc Mech Eng Press Vessels Pip Div., 406, pp. 25–31. http://jglobal.jst.go.jp/en/public/20090422/200902118118760088
Venter, A. M. , de Swardt, R. R. , and Kyriacou, S. , 2000, “ Comparative Measurements on Autofrettaged Cylinders With Large Bauschinger Reverse Yielding Regions,” J. Strain Anal. Eng. Des., 35(6), pp. 459–469. [CrossRef]
Kamal, S. M. , and Dixit, U. S. , 2015, “ Feasibility Study of Thermal Autofrettage Process,” Advances in Material Forming and Joining, R. G. Narayanan , and U. S. Dixit , eds., Springer, New Delhi, pp. 81–107.
Kamal, S. M. , Borsaikia, A. C. , and Dixit, U. S. , 2016, “ Experimental Assessment of Residual Stresses Induced by the Thermal Autofrettage of Thick-Walled Cylinders,” J. Strain Anal. Eng. Des., 51(2), pp. 144–160. [CrossRef]
Zare, H. R. , and Darijani, H. , 2016, “ A Novel Autofrettage Method for Strengthening and Design of Thick-Walled Cylinders,” Mater. Des., 105, pp. 366–374. [CrossRef]
Shufen, R. , and Dixit, U. S. , 2017, “ A Finite Element Method Study of Combined Hydraulic and Thermal Autofrettage Process,” ASME J. Pressure Vessel Technol., 139(4), p. 041204. [CrossRef]
Chakrabarty, J. , 2006, Theory of Plasticity, 3rd ed., Butterworth-Heinemann, Burlington, MA.
Dixit, P. M. , and Dixit, U. S. , 2008, Modeling of Metal Forming and Machining Processes: By Finite Element and Soft Computing Methods, Springer, London.
Gerald, C. F. , and Wheatley, P. O. , 1994, Applied Numerical Analysis, 5th ed., Addison-Wesley, Boston, MA.

Figures

Grahic Jump Location
Fig. 1

The elastic and plastic zones in the quadrant of a disk subjected to rotational speed ω

Grahic Jump Location
Fig. 2

Elasto-plastic stress distribution in the SS304 disk for ω = 700 rad/s

Grahic Jump Location
Fig. 3

Residual stress distribution in the SS304 disk

Grahic Jump Location
Fig. 4

Net stress distribution in the autofrettaged SS304 disk for an internal pressure of 128.2 MPa

Grahic Jump Location
Fig. 5

Net stress distribution in the autofrettaged SS304 disk for (TbTa) =129 °C

Grahic Jump Location
Fig. 6

Net stress distribution in the autofrettaged SS304 disk for ω = 689 rad/s

Grahic Jump Location
Fig. 7

Elasto-plastic stress distribution in the aluminum disk for ω = 850 rad/s

Grahic Jump Location
Fig. 8

Residual stress distribution in the aluminum disk

Grahic Jump Location
Fig. 9

Net stress distribution in the autofrettaged aluminum disk for an internal pressure of 24.9 MPa

Grahic Jump Location
Fig. 10

Net stress distribution in the autofrettaged aluminum disk for (TbTa) =70 °C

Grahic Jump Location
Fig. 11

Net stress distribution in the autofrettaged aluminum disk for ω = 841 rad/s

Grahic Jump Location
Fig. 12

Comparison of the theoretical (a) elasto-plastic stresses and (b) residual stresses with 3D FEM analysis in SS304 disk subjected to rotational autofrettage

Tables

Errata

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In