Professional Documents
Culture Documents
VVS2018-9309
MODELING AND VALIDATING
RESIDUAL STRESSES IN THICK-
WALLED CYLINDERS
Zhong Hu, Ph.D.
Professor of Mechanical Engineering Department
South Dakota State University, Brookings, SD 57007, USA
Phone: (605) 688-4817, Fax: (605) 688-5878
E-mail: Zhong.Hu@sdstate.edu
ResearchGate Website: https://www.researchgate.net/profile/Zhong_Hu
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 2
Presentation Outlines
1. Introduction
2. Autofrettage Processes
3. Modeling Of Swage Autofrettage Processes
4. Validation by Sachs Boring Technique
5. Validation by Neutron Diffraction Measurements
6. Modeling Comparison between ANSYS and
ABAQUS
7. Conclusions
Acknowledgements
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 3
1. Introduction
Gun Barrel
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 4
Basic Assumptions:
• Static loads
• Isotropic and homogenous
material
• Constant temperature
• Elasto-plastic and small
deformation
• Open ended. Ignoring axial
load (stress)
• Cross section keeping plane
after deformation
Strain-Displacement Relations
Stress Components under
Internal and External Pressure
(Lamé Equations):
1
b/a = 1.5
0
3
0 20 40 60 80 100
σθ/p1
-1
Normalized radial position (%) 2
1
-2 p2/p1=0
p2/p1=0.5 0
p2/p1=1
-3 0 20 40 60 80 100
σθ/p1
p2/p1=1.5
p2/p1=2 -1 Normalized radial position (%)
-4 -2
p2/p1=0
-3 p2/p1=0.5
b/a = 2 p2/p1=1
-4 p2/p1=1.5
p2/p1=2
-5
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 8
2. Autofrettage Processes
To improve the performance of an internal pressurized thick-
walled cylinder, favorable compressive residual stresses can be
produced near the bore of the cylinder, commonly by an
autofrettage process prior to use.
Autofrettage is a metal fabrication technique in which a pressure
vessel is subjected to enormous pressure, causing internal portions
of the part to yield plastically, resulting in internal compressive
residual stresses once the pressure is released.
Goal of autofrettage: is to increase the durability of the final
product. Inducing residual compressive stresses (hoop and axial)
into materials can also increase their resistance to stress corrosion
cracking.
Classification of autofrettage: Hydraulic autofrettage, Double-layer
autofrettage, Swage autofrettage, Explosive autofrettage, Thermal
Explosive Bonded Ring
autofrettage, Rotational autofrettage.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 9
Z. Hu and S. Puttagunta. Computer modeling of internal pressure autofrettage process of a thick-walled cylinder with the Bauschinger effect. American Transactions on Engineering & Applied
Sciences, 1(2)(2012)143-161.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 10
Z. Hu. Design and modeling of internally pressurized thick-walled cylinder. 2010 NDIA Conference, Dallas, TX, May 17-20, 2010
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 11
J. D. Mote, et al. Explosive autofrettage of cannon barrels. Final Report – Contract DAAG46-69-C-0061, Army Materials and Mechanics Research Center, Watertown, MA, Feb. 24, 1971
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 12
H. R. Zare and H. Darijani. Strengthening and design of the linear hardening thick-walled cylinders using the new method of rotational autofrettage. Int J Mechanical Sciences, 124-125(2017)1-8.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 14
M. C. Gibson, et al. Investigation of residual stress development during swage autofrettage, using finite element analysis. J Pressure Vessel Technology 134(2014)023206-1~7
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 15
Z. Hu. Design of two-pass swage autofrettage processes of thick-walled cylinders by computer modeling. Proc IMechE Part C: J Mechanical Engineering Science, 2018
Z. Hu. and C. Penumarthy. Computer modeling and optimization of swage autofrettage process of a thick-walled cylinder incorporating Bauschinger effect. American Transactions on
Engineering & Applied Sciences, 3(1)(2014)31-63.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 16
Swage on halfway
Swage removed
(residual stress)
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 18
Swage on halfway
Swage removed
(residual stress)
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 19
Swage on halfway
Swage removed
(residual stress)
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 20
1.5E+9
-1.5E+9
J. Perry, Experimental-Numerical Three-Dimensional Model for Calculating the Residual Stress Field Created by the Autofrettage Process. Ph.D. Thesis. Ben-Gurion University of the Negev, 2009.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 23
Pa psi
1.00E+09 1.45E+05
5.00E+08 7.25E+04
0.00E+00 0.00E+00
-5.00E+08 -7.25E+04
-1.00E+09 -1.45E+05
1.0E+9
K1.5, FL16.7mm, 1.14% Interference, 0.472% PBE
Radial Stress
5.0E+8 Axial Stress
Hoop Stress
-5.0E+8
-1.0E+9
T. E. Davidson, et al. Technical Report - Residual stresses in thick-walled cylinders resulting from mechanically induced overstrain. 38 pages, Benet R&E Laboratories, Watervliet, NW, September 1963.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 24
Pa psi
1.50E+09 2.18E+05
1.00E+09 1.45E+05
5.00E+08 7.25E+04
0.00E+00 0.00E+00
-5.00E+08 -7.25E+04
-1.00E+09 -1.45E+05
-1.50E+09 -2.18E+05
1.5E+9
K1.5, FL16.7mm, 4.6% Interference, 3.8% PBE
1.0E+9
Radial Stress
0.0E+0
0 20 40 60 80 100
-1.0E+9
T. E. Davidson, et al. Technical Report - Residual stresses in thick-walled cylinders resulting from mechanically induced overstrain. 38 pages, Benet R&E Laboratories, Watervliet, NW, September 1963.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 25
Pa psi
1.50E+09 2.18E+05
1.00E+09 1.45E+05
5.00E+08 7.25E+04
0.00E+00 0.00E+00
-5.00E+08 -7.25E+04
-1.00E+09 -1.45E+05
-1.50E+09 -2.18E+05
1.5E+9
5.0E+8
0.0E+0
0 20 40 60 80 100
Normalized Radial Position (%)
-5.0E+8
-1.0E+9
T. E. Davidson, et al. Technical Report - Residual stresses in thick-walled cylinders resulting from mechanically induced overstrain. 38 pages, Benet R&E Laboratories, Watervliet, NW, September 1963.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 26
Pa psi
1.50E+09 2.18E+05
1.00E+09 1.45E+05
5.00E+08 7.25E+04
0.00E+00 0.00E+00
-5.00E+08 -7.25E+04
-1.00E+09 -1.45E+05
-1.50E+09 -2.18E+05
5.0E+8
K1.9, FL16.7mm, 1% Interference, 0.398% PBE
2.5E+8
-7.5E+8
-1.0E+9
T. E. Davidson, et al. Technical Report - Residual stresses in thick-walled cylinders resulting from mechanically induced overstrain. 38 pages, Benet R&E Laboratories, Watervliet, NW, September 1963.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 27
Pa psi
1.50E+09 2.18E+05
1.00E+09 1.45E+05
5.00E+08 7.25E+04
0.00E+00 0.00E+00
-5.00E+08 -7.25E+04
-1.00E+09 -1.45E+05
-1.50E+09 -2.18E+05
1.0E+9
K1.9, FL16.7mm, 4.4% Interference, 3.62% PBE
5.0E+8
-1.0E+9
T. E. Davidson, et al. Technical Report - Residual stresses in thick-walled cylinders resulting from mechanically induced overstrain. 38 pages, Benet R&E Laboratories, Watervliet, NW, September 1963.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 28
Pa psi
1.50E+09 2.18E+05
1.00E+09 1.45E+05
5.00E+08 7.25E+04
0.00E+00 0.00E+00
-5.00E+08 -7.25E+04
-1.00E+09 -1.45E+05
-1.50E+09 -2.18E+05
1.5E+9
K1.9, FL16.7mm, 6.3% Interference, 5.6% PBE
Radial Stress
1.0E+9 Axial Stress
Hoop Stress
0.0E+0
0 20 40 60 80 100
-1.0E+9
T. E. Davidson, et al. Technical Report - Residual stresses in thick-walled cylinders resulting from mechanically induced overstrain. 38 pages, Benet R&E Laboratories, Watervliet, NW, September 1963.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 29
Pa psi
1.50E+09 2.18E+05
1.00E+09 1.45E+05
5.00E+08 7.25E+04
0.00E+00 0.00E+00
-5.00E+08 -7.25E+04
-1.00E+09 -1.45E+05
-1.50E+09 -2.18E+05
5.0E+8
K2.3, FL16.7mm, 0.95% Interference, 0.362% PBE
0.0E+0
0 20 40 60 80 100
Residual Stresses (Pa) Normalized Radial Position (%)
-5.0E+8
Radial Stress
Axial Stress
Hoop Stress
-1.0E+9
-1.5E+9
T. E. Davidson, et al. Technical Report - Residual stresses in thick-walled cylinders resulting from mechanically induced overstrain. 38 pages, Benet R&E Laboratories, Watervliet, NW, September 1963.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 30
Pa psi
1.50E+09 2.18E+05
1.00E+09 1.45E+05
5.00E+08 7.25E+04
0.00E+00 0.00E+00
-5.00E+08 -7.25E+04
-1.00E+09 -1.45E+05
-1.50E+09 -2.18E+05
1.0E+9
K2.3, FL16.7mm, 3% Interference, 2.16% PBE
Radial Stress
5.0E+8 Axial Stress
Hoop Stress
Residual Stresses (Pa)
0.0E+0
0 20 40 60 80 100
-1.0E+9
-1.5E+9
T. E. Davidson, et al. Technical Report - Residual stresses in thick-walled cylinders resulting from mechanically induced overstrain. 38 pages, Benet R&E Laboratories, Watervliet, NW, September 1963.
May 16-18, 2018, Minneapolis, MN, USA
Z. Hu. Design of two-pass swage autofrettage processes of thick-walled cylinders by computer modeling. Proc IMechE Part C: J Mechanical Engineering Science, 2018
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 33
J.H. Underwood, et al. Hill stress calculations for autofrettaged tubes compared with neutron diffraction residual stresses and measured yield pressure and fatigue life. ASME 2007 Pressure Vessels
and Piping Conference (PVP2007-26617), 47-52, San Antonio, TX, 22-26 July 2007.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 35
J.H. Underwood, et al. Hill stress calculations for autofrettaged tubes compared with neutron diffraction residual stresses and measured yield pressure and fatigue life. ASME 2007 Pressure Vessels
and Piping Conference (PVP2007-26617), 47-52, San Antonio, TX, 22-26 July 2007.
Modeling and Validating Residual Stresses in Tick-Walled Cylinders 36
ABAQUS ANSYS
ANSYS
ABAQUS
7. CONCLUSIONS
ACKNOWLEDGEMENTS