STAFFORDSHIRE UNIVERSITY

Assignment 1: Determination of Stresses and Strains in Thick Cylinder

Submitted by: Mohamed Humaid Al-Badri (09032170) Email: aw032170@student.staffs.ac.uk Award Title: Mechanical Engineering Module Title: Applied Structural Integrity Module Code: CE00449-7 Submitted to: Prof. Peter Ogrodnik

Submission Date: 25/11/2011

Abstract

Thick walled cylinder under internal pressure widely used in many industry applications. Here we did an experiment on the thick walled cylinder under internal pressure and got the reading for strains from 10 gauges jointed inside the cylinder wall. These strains are for radial and hoop, and then we calculated the stresses for it. Also, we analyzed the thick walled cylinder theoretically by using Lame equations. In addition, we analyzed the cylinder in Ansys in three ways 3D, plain strain and axis symmetric. Then, all radial and hoop stresses for the cylinder plotted in one graph to compare the results from each method. The results obtained shows that, there are always slightly differences between the values either for strains or stresses in thick walled cylinder taken from the experiment and the theoretical values, and this is during the human mistakes and equipments calibrations.

Table of Contents
List of Figures.....................................................................................................................................4 List of Tables ......................................................................................................................................4 Nomenclature ....................................................................................................................................5 1. Introduction: ..............................................................................................................................6 1.1 Assignment Background: .................................................................................................................... 6 2. Materials: ......................................................................................................................................7 3. Methods: .......................................................................................................................................7 3.1 Experimental Analysis for Thick Walled Cylinder under Internal Pressure: ....................................... 7 3.1.1 Description and Apparatus of the Experiment: ........................................................................... 7 3.1.2 General Information: ................................................................................................................... 8 3.1.3 Procedure:.................................................................................................................................... 8 3.2 Theory Analysis for Thick Walled Cylinder under Internal Pressure:................................................ 10 3.3 Ansys Analysis for Thick Walled Cylinder under Internal Pressure:.................................................. 12 3.3.1 (3D) Modeling: ........................................................................................................................... 12 3.3.2 Plain Strain (2D Modeling): ........................................................................................................ 15 3.3.3 Axis Symmetric: .......................................................................................................................... 18 4. Results and Conclusion: ................................................................................................................ 21 References:...................................................................................................................................... 25

List of Figures
Figure 1 Thick walled cylinder under internal pressure................................................................................ 6 Figure 2 Strain plot for all gauges for Run2 .................................................................................................. 9 Figure 3 Experimental radial and hoop stresses ......................................................................................... 10 Figure 4 Thick cylinder under internal pressure [2] .................................................................................... 10 Figure 5 Theoretical radial and hoop stresses ............................................................................................ 12 Figure 6 3D model meshes refinement....................................................................................................... 13 Figure 7 3D model analysis steps ................................................................................................................ 14 Figure 8 3D model radial and hoop stresses ............................................................................................... 15 Figure 9 Plain Strain (2D model) meshes refinement ................................................................................. 16 Figure 10 Plain strain (2D model) analysis steps......................................................................................... 17 Figure 11 Plain Strain (2D model) radial and hoop stresses ....................................................................... 18 Figure 12 Axis Symmetric meshes refinement ........................................................................................... 19 Figure 13 Axis symmetric model analysis steps .......................................................................................... 20 Figure 14 Axis Symmetric radial and hoop stresses.................................................................................... 21 Figure 15 Experimental and Theoretical values of strain against radius .................................................... 21 Figure 16 Experimental values of strain against pressure .......................................................................... 22 Figure 17 Radial stresses distributions in thick walled cylinder ................................................................. 23 Figure 18 Hoop stresses distributions in thick walled cylinder................................................................... 23

List of Tables
Table 1 Strain readings for Run 2 .................................................................................................................. 8 Table 2 Experimental radial and hoop stress for strain readings for Run 2 ................................................. 9 Table 3 Theoretical stresses ........................................................................................................................ 11

Nomenclature
FEM H r A B L E v P OD ID Finite Element Method Hoop Radial Constant Constant Length Stress Strain Youngs modules Poissons Ratio Pressure Outer Diameter Inner Diameter

1. Introduction:
Thick walled cylinders are now widely used in many applications like nuclear power plants for steam and power generation [1]. Some of the thick walled cylinder applications may have very high pressures as 1380 MPa and high tempreatures which can go up to , resulting in the pressure vessel material

holding immense potential energy exerted by the working fluid [1]. The high pressure for thick walled cylinder needs proper understanding of the stress levels and distributions along radial and hoop directions in order to minimize the probability of design failures. Moreover, the thick walled cylinder failures effects by material properties, type of fluid, and environmental interactions. Now days, the thick walled cylinder are great important in many industries and their economic use often depends upon the occurrence of small, controlled, permanent deformations [2]. In this report, we will do the experiment for the thick walled cylinder and analysis the strain readings and then calculate the radial and hoop stresses. Also, we will analysis the cylinder theoretically and by FEM using Ansys software. Then, present the results and compare between these methods.

1.1 Assignment Background: Determination of the radial and hoop stresses and strains in thick walled cylinder under internal pressure by doing an experiment as shown in Figure 1. Also, is to study the cylinder theoretically and obtain the strains and stresses values. In addition, is to analysis the cylinder in Ansys by three methods 3D, plain strain, and axis symmetric by refining the mesh, applying the boundary conditions and obtain the stresses. At the end, is to compare the all results and find the experimental errors.

Figure 1 Thick walled cylinder under internal pressure

2. Materials:
Duralumin (also called duraluminium or dural) is the name of the earliest type of age-hardenable aluminium alloys [3]. It is consider as a composite material and it consist of more than one material by different percentages, which are about 4.4% copper, 1.5% magnesium, 0.6% manganese and 93.5% of aluminium itself. The typical yield strength of this alloy is 450 MPa, with variations depending on the composition and temper. It had many developments during last century and now days mainly used in popular science to describe the Al-Cu alloy system. Also, it is popular for use in precision tools such as levels because of its light weight and strength. There are many typical uses for Al-Cu alloys like wire, rod, and bar for screw machine products. In addition, it is used widely in other fields like aircraft structures, rivets, hardware, truck wheels, and other miscellaneous structural applications [3].

3. Methods:
We will use three ways of investigation and evaluation of radial and hoop stresses and strain throughout the wall of the thick cylinder that experimental results, theoretical results, and Ansys results. Then, we will plot these results and compare between them.

3.1 Experimental Analysis for Thick Walled Cylinder under Internal Pressure: 3.1.1 Description and Apparatus of the Experiment: The experiment is to demonstrate and analyze the radial and hoop stresses in thick walled cylinder under internal pressure. The cylinder made of duralumin in two halves cemented together. The internal face subjected with 13 gauges to measure radial and hoop strains, which the corresponding stresses are calculated. The cylinder is mounted in a sturdy frame and the whole unit complete with a hydraulic hand pump for applying pressure is fitted to a modular steel base. All strain gauges are temperature

compensated and the cylinder pressure is measured by an internal transducer and also by a Bourdon gauge. These gauges connected to PC and get the reading of strains from the software. 3.1.2 General Information: Material Duralumin. Youngs Modulus (E) 68.95 MPa. Poissons Ratio (v) 0.33 Cylinder Length 203 mm. Cylinder OD 150 mm. Cylinder ID 37 mm. Max. Test Pressure 7 MPa. Calculation Test Pressure 3.5 MPa. Strain Gauges Electrical Resistance.

3.1.3 Procedure: 1. We, set the cylinder internal pressure at zero by checking that the hand wheel turns freely and the pressure gauge reads zero. 2. Then, we took the readings of strains at zero pressure. 3. Then, we increased the internal pressure by increments of 1MPa up to 6 MPa, allowing about 5 seconds for the pressure and strain to stabilize, and then for each increment we took the strain readings for the 10 gauges from PC screen. 4. Then, we putted all readings for radial and hoop strains in tables and calculate the radial and hoop stresses as shown in Table 1 and Table 2 for Run 2 as an example.

Table 1 Strain readings for Run 2

Pressure (MPa) 0.82 1.23 2.29 3.35 4.35 5.36 Gauge 1 8.22 12.15 22.80 33.27 43.36 53.64 Gauge 2 -9.16 -13.64 -25.42 -37.38 -48.22 -59.44 Gauge 3 5.23 7.66 14.58 20.93 27.48 34.02 Gauge 4 -4.30 -6.54 -12.15 -17.94 -23.18 -28.60 Gauge 5 3.36 5.05 9.53 13.83 17.94 22.24 Gauge 6 -2.24 -3.36 -6.17 -10.35 -11.78 -14.39 Gauge 7 2.24 3.55 6.54 9.72 12.70 15.70 Gauge 8 -1.87 -2.62 -4.86 -7.29 -9.16 -11.47 Gauge 9 1.87 2.62 5.23 7.10 9.72 11.96 Gauge 10 -1.31 -1.87 -3.36 -5.23 -6.54 -8.04

Table 2 Experimental radial and hoop stress for strain readings for Run 2
Gauge no. 1 2 3 4 5 6 7 8 9 10 Strain Type H R H R H R H R H R Equation 9.97 -11.10 6.32 -5.33 4.13 -2.76 2.91 -2.13 2.21 -1.51 Pressure (MPa) 3.50 3.50 3.50 3.50 3.50 3.50 3.50 3.50 3.50 3.50 Hoop Strain 34.90 -38.86 22.12 -18.66 14.46 -9.66 10.19 -7.46 7.74 -5.29 0.46 -0.21 0.60 -0.32 0.87 -0.38 1.24 -0.88 Radial Strain Hoop stress (MPa) 1.71 Radial Stress (MPa) -2.12

5. Then, we plotted the stain values for all gauges as shown in Figure 2.

60.00 y = 9.9764x 40.00 y = 6.3209x 20.00 y = 4.138x y = 2.9129x y = 2.2156x

0.00 0.00 -20.00 y = -5.3333x -40.00 1.00 2.00 3.00 4.00 5.00 y = -1.5102x y = -2.1361x y = -2.7622x 6.00

-60.00

y = -11.102x

-80.00 Gauge 1 Gauge 6 Linear (Gauge 1) Linear (Gauge 6) Gauge 2 Gauge 7 Linear (Gauge 2) Linear (Gauge 7) Gauge 3 Gauge 8 Linear (Gauge 3) Linear (Gauge 8) Gauge 4 Gauge 9 Linear (Gauge 4) Linear (Gauge 9) Gauge 5 Gauge 10 Linear (Gauge 5) Linear (Gauge 10)

Figure 2 Strain plot for all gauges for Run2

6. Then, we plotted the experimental values for radial and hoop stresses and it is shown in Figure 3 below.

Hoop stress 2.00 1.50 1.00 0.50 Stress (MPa) 0.00 -0.50 -1.00 -1.50 -2.00 -2.50 Radius (mm) 0.00 10.00 20.00 30.00

Radial stress

40.00

50.00

60.00

70.00

Figure 3 Experimental radial and hoop stresses

3.2 Theory Analysis for Thick Walled Cylinder under Internal Pressure: The Lame equations can be obtained for the thick cylinder subjected to a uniformly distributed internal pressure P, radius r [2] shown in Figure 4 as following.

Figure 4 Thick cylinder under internal pressure [2]

(1) (2) Where and are the radial and hoop stresses respectively, and A and B are constants, and the

strain values can be obtained from the following equations. (3)

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(4) (5) Where and are the radial, hoop and longitude strains for the cylinder. Since, there are inner radiuses for the thick cylinder under internal pressure P, so the general expressions

and outer

for radial and hoop stresses can be given by:

(6)

(7) By use values of radial and hoop strains from equations 3 & 4 and substitute into equations 6 & 7, we can get the stresses value from the experimental measured strains, and these equations for stress will be: (8) (9) According to equations 8 & 9, we calculated the radial and hoop stresses using the values of strains gained from the experiment and the results of these stresses are shown in Table 3.

Table 3 Theoretical stresses

Radius (mm)
28.00 36.00 45.00 56.00 63.00

Hoop stress (MPa)

1.85 1.21 0.86 0.63 0.55

Radial stress (MPa)

-1.40 -0.76 -0.40 -0.18 -0.09

And then we plot the stresses and it is shown in Figure 5 below.

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2.50 2.00 1.50 1.00 Stresses (MPa) 0.50 Hoop stress 0.00 0.00 -0.50 -1.00 -1.50 -2.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 Radial stress

Radius (mm)

Figure 5 Theoretical radial and hoop stresses

3.3 Ansys Analysis for Thick Walled Cylinder under Internal Pressure: We modeled the thick walled cylinder in Ansys in three different ways 3D model, plain strain (2D model) and axis- symmetric model, and here we will explain the method of modeling and gaining the results. 3.3.1 (3D) Modeling: We designed the thick walled cylinder in Ansys in 3D shape as given dimensions 203 mm length, 75 mm outer radius, and 18.5 mm inner radius and the test pressure is 3.5 MPa. The mesh was appearing as shown in Figure 6 (a), and then we refine the mesh in order to get the maximum value of the stress. After some trials, we end up with that maximum stress is 6.314 MPa at the number of elements 5698, as shown in Figure 6 (b) and (c), and then we consider this mesh for the analysis.

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(a) 3D model meshes before refinement

6.4

6.2

Equivalent Stress (MPa)

5.8

5.6

5.4

5.2

5 0 1000 2000 3000 No. of Elements 4000 5000 6000

(b) 3D model graph for meshes refinement (c) 3D model meshes after refinement Figure 6 3D model meshes refinement

After that, we applied the boundary conditions (pressure and displacements), and changed the coordinate system to cylindrical coordinate system and inserted path by using construction geometry and then we calculated for the radial and hoop stresses. The following Figure 7 (a), (b), and (c) shows these steps.

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(a) 3D model boundary conditions

(b) 3D model radial stresses

(c) 3D model hoop stresses Figure 7 3D model analysis steps

The radial and hoop stresses are close to that which we get it in experimental and theoretical as shown in the following Figure 8.

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5.00 4.00 3.00 2.00 Stress (MPa) 1.00 Hoop stress 0.00 0.00 -1.00 -2.00 -3.00 -4.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 Radial stress

Radius (mm)

Figure 8 3D model radial and hoop stresses

3.3.2 Plain Strain (2D Modeling): We designed the thick walled cylinder in Ansys in as a plain strain 2D model at same dimensions and the test pressure is 3.5 MPa. The mesh was appearing as shown in Figure 9 (a), and then we refine the mesh in order to get the maximum value of the stress. After some trials, we end up with that maximum stress is 6.445 MPa at the number of elements 594, as shown in Figure 9 (b) and (c), and then we consider this mesh for the analysis.

(a) Plain Strain (2D model) meshes before refinement

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6.5 6.45 6.4 6.35 6.3 6.25 6.2 0 100 200 300 400 500 600 700 No. of Elements

Stress (MPa)

(b) Plain Strain graph for meshes refinement

(c) Plain Strain meshes after refinement

Figure 9 Plain Strain (2D model) meshes refinement

After that, we applied the boundary conditions (pressure and displacements), and use global coordinate system and inserted path by using construction geometry and then we calculated for the radial and hoop stresses. The following Figure 10 (a), (b), and (c) shows these steps.

(a) Plain Strain boundary conditions

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(b) Plain Strain radial stresses

(c) Plain Strain hoop stresses Figure 10 Plain strain (2D model) analysis steps

The radial and hoop stresses for plain strain analysis are close to that which we get it in experimental and theoretical as shown in the following Figure 11.

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5.00

4.00

3.00

2.00 Stresses (MPa)

1.00 Hoop Stress 0.00 0.00 -1.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 Radial stress

-2.00

-3.00

-4.00

Radius (mm)

Figure 11 Plain Strain (2D model) radial and hoop stresses

3.3.3 Axis Symmetric: We designed the thick walled cylinder in Ansys in as an axis symmetric model at same dimensions and the test pressure is 3.5 MPa. The mesh was appearing as shown in Figure 12 (a), and then we refine the mesh in order to get the maximum value of the stress. After some trials, we end up with that maximum stress is 6.404 MPa at the number of elements 1596, as shown in Figure 12 (b) and (c), and then we consider this mesh for the analysis.

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(a) Axis Symmetric meshes before refinement

6.5 6.4 6.3 6.2 Stress (MPa) 6.1 6 5.9 5.8 5.7 5.6 0 200 400 600 800 1000 1200 1400 1600 1800 No. of Elements

(b) Axis Symmetric graph for meshes refinement

(c) Axis Symmetric meshes after refinement

Figure 12 Axis Symmetric meshes refinement

After that, we applied the boundary conditions (pressure and displacements), and inserted path by using construction geometry and then we calculated for the radial and hoop stresses. The following Figure 13 (a), (b), and (c) shows these steps.

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(a) Axis Symmetric boundary conditions

(b) Axis Symmetric radial stresses

(c) Axis Symmetric hoop stresses Figure 13 Axis symmetric model analysis steps

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The radial and hoop stresses for axis symmetric analysis are also close to that which we get it in experimental and theoretical as shown in the following Figure 14.

5.00 4.00 3.00 2.00 Stress (MPa) 1.00 Hoop stress 0.00 0.00 -1.00 -2.00 -3.00 -4.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 Radial stress

Radius (mm)

Figure 14 Axis Symmetric radial and hoop stresses

4. Results and Conclusion:

In view of the above the experimental and theoretical values of the strain against radial positions for all gauges is plotted as shown in Figure 15 below.

0.04 0.03 0.02 0.01 0 0 -0.01 -0.02 -0.03 -0.04 -0.05 Hoop strain - experimental Radial strain - experimental 10 20 30 40 50 60 70

Strain

Radius (mm)

Hoop strain - therotical

Radial strain - therotical

Figure 15 Experimental and Theoretical values of strain against radius

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This graph shows that, there is a slightly differences between the strain values taken from the experiment and those calculated theoretically. The reason of that is the readings taken during experiment consist of some mistakes because of equipments celebrations and human mistakes sometimes. The experimental values of strain against pressure for all gauges are plotted as shown in Figure 16 below.
60.00 y = 9.9764x 40.00 y = 6.3209x 20.00 y = 4.138x y = 2.9129x y = 2.2156x

0.00 0.00 -20.00 y = -5.3333x -40.00 1.00 2.00 3.00 4.00 5.00 y = -1.5102x y = -2.1361x y = -2.7622x 6.00

-60.00

y = -11.102x

-80.00 Gauge 1 Gauge 6 Linear (Gauge 1) Linear (Gauge 6) Gauge 2 Gauge 7 Linear (Gauge 2) Linear (Gauge 7) Gauge 3 Gauge 8 Linear (Gauge 3) Linear (Gauge 8) Gauge 4 Gauge 9 Linear (Gauge 4) Linear (Gauge 9) Gauge 5 Gauge 10 Linear (Gauge 5) Linear (Gauge 10)

Figure 16 Experimental values of strain against pressure

Also here we can compare all values of stresses either radial or hoop by plotting the experiment, theoretical and Ansys values in the following Figures 17 and 18.

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0.00 1.00 0.50 0.00 -0.50 Radiul Stress(MPa) -1.00 -1.50 -2.00 -2.50 -3.00 -3.50 -4.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

Radius (mm)

Run 1 Run 5 3D

Run 2 Run 6 Axsymmetric

Run 3 Run 7 Plane Strain

Run 4 Therotical results

Figure 17 Radial stresses distributions in thick walled cylinder

4.50 4.00 3.50 Hoope's Stress (MPa) 3.00 2.50 2.00 1.50 1.00 0.50 0.00 0.00 10.00 20.00 30.00 40.00 Radius (mm) 50.00 60.00 70.00 80.00

Run 1 Run 5 Ansys 3D

Run 2 Run 6 Axisymmetric

Run 3 Run 7 Plane strain

Run 4 Therotical result

Figure 18 Hoop stresses distributions in thick walled cylinder

From the radial and hoop stresses plot we found that, there is small differences between the values which taken from experiment and the other values from theoretical and from Ansys analysis. In general, the hoop stresses increased during increasing the internal pressure and the radial decreases at the same time.

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In view of the above, there are always slightly differences between the values either for strains or stresses in thick walled cylinder taken from the experiment and the theoretical values. Also, the Ansys analysis gives butter prediction of the stresses as we refine the mesh to become pretty and approach the maximum pressure. Moreover, the values of all methods used to predict the strain and stresses in thick cylinder are close and there is small error only during the human mistakes and equipments calibrations.

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References:
[1] J.M. Kihiu, S. M. Mutuli and G. O. Rading, Stress characterization of autofrettaged thick walled cylinder (1986). [2] H. Ford, E. H. Watson and B. Crossland, Thought on a code of practice for forged high pressure vessels of monobloc design, Transactions of ASME, (1981). [3] C. T. F. Ross, Advanced applied stress analysis, Ellis Horwood Limited, New York (1987).

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