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Research Papers: Design and Analysis

Analysis of Residual Stresses in the Transition Zone of Tube-to-Tubesheet Joints

[+] Author and Article Information
Abdel-Hakim Bouzid

Fellow ASME
École de Technologie Supéreure,
1100, rue Notre-Dame Ouest,
Montréal, QC H3C 1K3, Canada
e-mail: hakim.bouzid@etsmtl.ca

Mohammad Pourreza

École de Technologie Supérieure,
1100, rue Notre-Dame Ouest,
Montréal, QC H3C 1K3, Canada
e-mail: pourrezamh@@gmail.com

1Corresponding author.

Manuscript received August 28, 2018; final manuscript received March 21, 2019; published online May 8, 2019. Assoc. Editor: Akira Maekawa.

J. Pressure Vessel Technol 141(4), 041201 (May 08, 2019) (11 pages) Paper No: PVT-18-1172; doi: 10.1115/1.4043374 History: Received August 28, 2018; Revised March 21, 2019

The rigorous stress analysis of tube-to-tubesheet joints requires a particular attention to the transition zone of the expanded tube because of its impact on joint integrity. This zone is the weakest part of the joint due to the presence of high tensile residual stresses produced during the expansion process, which coupled to in-service loadings and harsh corrosive fluids results in joint failure. In fact, it is often subjected to stress corrosion cracking caused by intergranular attack leading to plant shutdown. Therefore, the evaluation of the residual stresses in this zone is of major interest during the design phase and its accurate assessment is necessary to achieve a reliable joint in service. In this study, an analytical model to evaluate the residual axial and hoop stresses in the transition zone of hydraulically expanded tubes based on an elastic perfectly plastic material behavior has been developed. The model is capable of predicting the stress state when maximum expansion pressure is applied and after its release. Three main regions are identified in the transition zone: the fully plastic region, the partially plastic region, and the elastic region. Therefore, various theories have been applied to analyze the stresses and deformations neglecting the elastoplastic region because of simplicity. The validation of analytical model is conducted by comparison of the results with those of 3D finite element models of two typical joints of different geometries and mechanical properties. The effect strain hardening and reverse yielding of the expansion zone are also investigated.

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References

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Figures

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Fig. 1

Schematic of different regions in transition zone

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Fig. 2

Cylindrical shell subjected to a ring load

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Fig. 4

Semi-infinite beam with bending moment and force

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Fig. 5

Long thin-walled cylindrical shell subjected to external pressure

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Fig. 6

Symmetric 3D model of tube to tubesheet connection

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Fig. 7

Comparison of stresses at tube inner surface at maximum expansion pressure, case 1

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Fig. 8

Comparison of stresses at tube outer surface at maximum expansion pressure, case 1

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Fig. 9

Comparison of residual stresses at tube inner surface after unloading, case 1

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Fig. 10

Comparison of residual stresses at tube outer surface after unloading, case 1

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Fig. 11

Comparison of radial displacement, case 1

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Fig. 12

Comparison of stresses at tube inner surface at maximum expansion pressure, case 2

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Fig. 13

Comparison of stresses at tube outer surface at maximum expansion pressure, case 2

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Fig. 14

Comparison of residual stresses at tube inner surface after unloading, case 2

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Fig. 15

Comparison of residual stresses at tube outer surface after unloading, case 2

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Fig. 16

Comparison of displacement, case 2

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Fig. 17

Tube and tubesheet true material behavior with strain hardening

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Fig. 18

Comparison of stresses at tube inner surface at maximum expansion pressure: Effect of strain hardening

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Fig. 19

Comparison of stresses at tube outer surface at maximum expansion pressure: Effect of strain hardening

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Fig. 20

Comparison of residual stresses at tube inner surface after unloading: Effect of strain hardening

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Fig. 21

Comparison of residual stresses at tube outer surface after unloading: Effect of strain hardening

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Fig. 22

Stresses and displacement in a long thin-walled cylindrical shell subjected to a band pressure

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