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Lecture Notes
Introduction to Strength of Materials
pp. 1
7. Design of pressure vessels and Transformation of plane stress
Contents
7. Design of pressure vessels and Transformation of plane stress ......................................................... 1
7.1 Introduction .................................................................................................................................................... 2
7.2 Design of pressure vessels......................................................................................................................... 2
7.2.1 The cylindrical case ............................................................................................................................ 2
7.2.2 The spherical case ............................................................................................................................... 3
7.2.3 Practical considerations ................................................................................................................... 4
7.3 Transformation of plane stress ............................................................................................................... 4
7.3.1 Principal stresses ................................................................................................................................. 4
7.3.2 The transformation equations ....................................................................................................... 5
7.3.3 Mohrโs circle .......................................................................................................................................... 6
Calculated example 7A: Transformation of plane stress ........................................................................ 9
Calculated example 7B: Pressure vessel with helical welding .......................................................... 10
Calculated example 7C: stresses in a beam section ............................................................................... 12
Problems ........................................................................................................................................................................... 13
Lecture Notes
Introduction to Strength of Materials
pp. 2
7.1 Introduction In the present chapter, we will start out by considering stresses in thin-walled pressure vessels and pipe lines. Before a theoretical understanding of fatigue crack formation and stresses in thin-walled pipelines and pressure vessels were established, catastrophic failure of pressure carrying equipment led to a very high loss of human lives in the age of industrialization in the 19th century. Examples of failures are shown in Figure 7-1, which contain examples of what we are designing against. Once we have gotten the hang of this, we will continue by considering transformations of plane states of stress along with a very common and quite useful visualization of the transformation known as Mohrโs circle. The above mentioned topics are usually considered together, though they at first sight do seem rather unrelated. The reason for this is, that stresses in thin-walled pressure chambers are a splendid example of a state of plane stress though the geometry is curved. We therefore remember from the very beginning that plane stress refers to the stress state and the geometry does not necessarily have to plane.
7.2 Design of pressure vessels Rupture of pressure vessels and pipelines caused by overstressing due to internal pressure is called burst and the internal pressure leading to failure is called the burst pressure. It is important to note the following:
โข External pressure may lead to collapse โ an instability failure mode (buckling), which differs from burst
โข Design is usually based on thin shell theory: ๐/๐ก > 10 based on symmetry in loads and geometry
โข If correctly designed, the shell is only subjected to membrame stresses (i.e. there will be no stresses due to bending)
Figure 7-1 Left: Failure of pressure chamber during testing. Note the characteristic rupture in the longitudinal direction, Right: Catastrophic failure of steam engine driven locomotive (Pictures from Wikimedia)
In order to obtain design formulas for the stresses in a vessel due to internal pressure, we will consider the internal forces acting inside the walls of pressure vessels in the following.
7.2.1 The cylindrical case We will consider a section in the longitudinal direction through a cylindrical pressure vessel with mean radius r, wall thickness t and internal pressure p, see Figure 7-2. We imagine that the vessel contains a medium that transfers the load from the considered section to the pipe wall. The stress ฯ1 in the pipe wall corresponds to the force F1=ฯ12bt (internal forces). The pressure
Lecture Notes
Introduction to Strength of Materials
pp. 3
in the section generates a force ๐1 = 2๐๐๐ (external forces). Since the internal and external actions most balance each other in order to maintain static equilibrium, we have 0 = ๐น1 โ ๐1 = ฯ12bt โ 2๐๐๐
โ 0 = ฯ1t โ ๐๐
โ ฯ1 =๐๐
๐ก
(7-1)
We now consider a section through the radial direction of the pressure vessel (again containing a medium that transfers forces). The stresses in the pipe wall corresponds to the internal force F2=ฯ22ฯrt. The pressure on the other hand generates the external load ๐2 = ๐๐๐2. Again, demanding the external and internal forces to balance each other to obtain equilibrium, we have 0 = ๐น2 โ ๐2 = ฯ22ฯrt โ ๐๐๐2
โ 0 = ฯ22t โ ๐๐
โ ฯ2 =๐๐
2๐ก
(7-2)
In the radial direction the stress varies from โp on the inner side to 0 on the outer side. These terms are small compared to the stresses in the other directions and are therefore neglected. Formally, we write ฯ3 โช ฯ1, ฯ2 โ ฯ3 โ 0. We conclude that the axial stresses are half as large as the radial stresses and that equilibrium is maintained without presence of shear stresses, i.e. these are zero.
Figure 7-2 Cylindrical pressure vessel (or pipeline) subjected to internal pressure
7.2.2 The spherical case The stresses in a spherical pressure vessel can be calculated in exactly the same fashion as shown above and the derivation is therefore not concluded. However, if we go through with the calculations, we obtain the result ฯ1 = ฯ2 =
๐๐
2๐ก (7-3)
for two directions on the surface. For the radial direction, we again have ฯ3 โช ฯ1, ฯ2 โ ฯ3 โ 0. When comparing the result in equation (7-3) with the expressions for a cylindrical case, it is
Lecture Notes
Introduction to Strength of Materials
pp. 4
clear that the stress level is lower in a spherical geometry. Cylindrical pressure vessels are actually sub-optimal from a strict structural mechanics perspective. However, since cylindrical shapes are easier to handle, fit into a plant and often more suited for transport, these are widely applied due to simple practical considerations.
7.2.3 Practical considerations When designing pressure carrying equipment, it is of great importance to remember, that a number of factors govern the design which not only can be based on stress calculations using the formulas above. Some of the factors to remember are:
Pressure carrying equipment should contain pressure relief valves (PSV) preventing the pressure in the system to cause burst
When a tank is emptied, a vacuum may appear inside the tank. This has an effect similar to an external pressure and may collapse the tank. In many cases, this can be resolved by adding a valve at the top of a tank, which not only functions as PSV, but also opens if the pressure drops below atmospheric level so the tank is filled with air. This does not only apply for fluids, but also for systems storing solid particles.
An appropriate design stress criteria, usally von Mises, must be applied to the stresses ฯ1 and ฯ2 to obtain a reference stress for design.
End caps and man-holes induce stress concentrations and must be calculated separately. These are not accounted for in the present framework. Especially the transition from a cylindrical sweep to a spherical end cap requires attention and is often designed using FEA.
Most pressure carrying equipment is tested with 1.5 times the design pressure prior to service to ensure the integrity of the design.
The collapse pressure of a cylindrical pressure vessel or pipeline subjected to external pressure is given by (result from thin shell theory solved as bifurcation buckling problem): ๐๐ธ =
2๐ธ
1โ๐2
1
(๐ท
๐กโ1)
2 (7-4)
This formula does not account for ovalization due to manufacturing faults or bending. These effects might reduce the collapse pressure severely and requires further analysis.
7.3 Transformation of plane stress
7.3.1 Principal stresses We recall from chapter 1, that the stresses on the oblique section depend on the angle of the section. An axially loaded bar will now be considered. The stresses on the oblique section vary harmonically as functions of the angle, see Figure 7-3. We derived the expressions
๐ =๐น
๐ด0๐๐๐ 2๐ ๐ =
๐น
๐ด0๐๐๐ ๐ ๐ ๐๐๐
A direction for which the shear stresses vanish and leave us with a state of pure normal stress is called a principal direction. The corresponding normal stresses are called principal stresses. In the present example the first principal direction is the axial direction in which the load is applied and the corresponding principal stress is F/A0. The second principal direction perpendicular to the first direction and the corresponding principal stress is 0 (minimum normal stress value). We observed that the shear stress is 0 in both principal directions. A transformation to principal coordinates gives us maximum normal stresses and no shear.
Lecture Notes
Introduction to Strength of Materials
pp. 5
Figure 7-3 Left: Stresses on the oblique section of an axially loaded bar, Right: Normal and shear stresses as function of the oblique angle A state of stress is said to be plane if it can be described in terms of two normal components, ๐๐ฅ and ๐๐ฆ along with a shear component ๐๐ฅ๐ฆ (I.e. the remaining stress components must be zero โ
or sufficiently small to be neglected). A thin-walled pipeline subjected to internal pressure with stresses
ฯ1 =๐๐
๐ก ฯ2 =
๐๐
2๐ก
is also in a state of plane stress. We note that the shear stress is zero, i.e. this is a principal state of stress and the axial and hoop directions are principal directions. If different sections were chosen, shear stress components would emerge. We may say, that the stress state has been transformed by rotation if a different section is chosen.
Figure 7-4 Left: stress components on a small segment of material in plane stress, Right: Principal directions in a cylindrical pressure vessel
7.3.2 The transformation equations A set of equations relating two states of plane stress in two different coordinate systems will
now be derived. If the stress equilibrium of a small oblique section of an elastic body in plane
stress is considered, the stress states in the two coordinate systems xyz and xโyโzโ (with z=zโ) are
to be related, see Figure 7-5. Since a stress state has three components (two normal and one
shear stress component), this is slightly more complicated than conventional plane
transformations.
Lecture Notes
Introduction to Strength of Materials
pp. 6
Figure 7-5 Two states of plane stress related by the stress transformation equations The system xโyโzโ is obtained by rotating xyz counter clockwise. If we sum up the stress projections of the stress components in the xy system and project them onto the xโyโ axes, we obtain the three equations
๐๐ฅโฒ =๐๐ฅ + ๐๐ฆ
2+
๐๐ฅ โ ๐๐ฆ
2๐๐๐ (2๐) + ๐๐ฅ๐ฆ๐ ๐๐(2๐) (7-5)
๐๐ฆโฒ =
๐๐ฅ + ๐๐ฆ
2โ
๐๐ฅ โ ๐๐ฆ
2๐๐๐ (2๐) โ ๐๐ฅ๐ฆ๐ ๐๐(2๐) (7-6)
๐๐ฅโฒ๐ฆโฒ = โ๐๐ฅ โ ๐๐ฆ
2๐ ๐๐(2๐) + ๐๐ฅ๐ฆ๐๐๐ (2๐) (7-7)
These can be applied to transform a state of plane stress from one section to another. We will now on basis of the stress transformation equations derive a practical visualization known as Mohrโs circle for plane stress. Before proceeding, it is noted that if a small element is rotated with an angle of ฮธ, the angle applied in the transformation equations is 2ฮธ. This will also apply when rotating stress states using Mohrโs circle.
7.3.3 Mohrโs circle Rearranging and squaring the expression for ๐๐ฅโฒ we obtain
๐๐ฅโฒ =๐๐ฅ+๐๐ฆ
2+
๐๐ฅโ๐๐ฆ
2๐๐๐ (2๐) + ๐๐ฅ๐ฆ๐ ๐๐(2๐)
โ (๐๐ฅโฒ โ๐๐ฅ+๐๐ฆ
2)
2= (
๐๐ฅโ๐๐ฆ
2๐๐๐ (2๐) + ๐๐ฅ๐ฆ๐ ๐๐(2๐))
2
(7-8)
Squaring the expression for ๐๐ฅโฒ๐ฆโฒ we get
๐๐ฅโฒ๐ฆโฒ = โ๐๐ฅโ๐๐ฆ
2๐ ๐๐(2๐) + ๐๐ฅ๐ฆ๐๐๐ (2๐)
โ (๐๐ฅโฒ๐ฆโฒ)2
= (โ๐๐ฅโ๐๐ฆ
2๐ ๐๐(2๐) + ๐๐ฅ๐ฆ๐๐๐ (2๐))
2
(7-9)
Adding equations (I) and (II) we obtain
(๐๐ฅโฒ โ๐๐ฅ + ๐๐ฆ
2)
2
+ (๐๐ฅโฒ๐ฆโฒ)2
= (๐๐ฅ โ ๐๐ฆ
2๐๐๐ (2๐) + ๐๐ฅ๐ฆ๐ ๐๐(2๐))
2
+ (โ๐๐ฅ โ ๐๐ฆ
2๐ ๐๐(2๐) + ๐๐ฅ๐ฆ๐๐๐ (2๐))
2
โ (๐๐ฅโฒ โ๐๐ฅ + ๐๐ฆ
2)
2
+ (๐๐ฅโฒ๐ฆโฒ)2
= (๐๐ฅ โ ๐๐ฆ
2)
2
+ (๐๐ฅ๐ฆ)2
(7-10)
Lecture Notes
Introduction to Strength of Materials
pp. 7
This is recognized as the equation of a circle with radius ๐ = โ (๐๐ฅโ๐๐ฆ
2)
2+ (๐๐ฅ๐ฆ)
2 and center
(๐๐, 0) = (๐๐ฅ+๐๐ฆ
2, 0). We call this Mohrโs circle named after the German engineer Christian Otto
Mohr. For a shear stress oriented as shown (ฯ>0) we draw the circle by the following steps
1. Calculate R and ๐๐ 2. Plot (๐๐, 0) along with the two points (๐๐ฅ, โ๐๐ฅ๐ฆ) and (๐๐ฆ, ๐๐ฅ๐ฆ)
3. Draw the circle as shown below in Figure 7-6
Figure 7-6 Drawing Mohrโs circle I For a shear stress oriented as shown (ฯ<0), the points on the circumference will be located in a slightly differently, see Figure 7-7.
Figure 7-7 Drawing Mohrโs circle II
Lecture Notes
Introduction to Strength of Materials
pp. 8
By drawing Mohrโs circle, we can: โข Determine the principal stresses ๐๐๐๐ฅ and ๐๐๐๐ (also called ๐1 and ๐2) as intersections
with x-axis and the corresponding rotation required to obtain those (the angle ๐) โข Determine the maximum shear stress ๐๐๐๐ฅ found for a rotation of 45 deg. from the
principal stresses โข Carry out transformation of plane stress states graphically
That is eventually rather handy. As examples, we may construct Mohrโs circle for a few common stress states we have considered earlier in the course.
A.
B.
C.
Figure 7-8 Mohrโs circle for A. a thin-walled pressure vessel subjected to internal pressure, B. an oblique section in an axially loaded bar, C. A shaft in pure torsion
Lecture Notes
Introduction to Strength of Materials
pp. 9
Calculated example 7A: Transformation of plane stress For the plane stress segment shown, the stress components are given by ฯx=40 N/mm2, ฯy=-30 N/mm2 and ฯxy=20 N/mm2. Calculate a) the principal stresses, b) the corresponding angle of rotation, c) Furthermore, draw Mohrโs circle for the stress state shown, d) calculate the maximum shear stress and the corresponding angle of rotation.
Figure 7-9
Solution: a) The principal stresses are calculated by
๐๐๐ฃ =๐1+๐2
2=
40โ30
2
๐
๐๐2
๐ = โ (๐๐ฅโ๐๐ฆ
2)
2+ (๐๐ฅ๐ฆ)
2=โ (
40โ(โ30)
2)
2+ (20)2 ๐
๐๐2 = 40.3๐
๐๐2
๐1 = ๐๐๐ฃ + ๐ = 45.3๐
๐๐2 ๐2 = ๐๐๐ฃ โ ๐ = โ35.3๐
๐๐2
b) The angle of rotation required to obtained the principal coordinates is given by
tan(2๐) =2๐๐ฅ๐ฆ
๐๐ฅโ๐๐ฆ=
2โ20
40โ(โ30)โ ๐1 = 14.87 deg (counter-clockwise)
c) Mohrโs circle can now be drawn
Figure 7-10 d) The maximum shear stress is given by
๐๐๐๐ฅ = ๐ = 40.3๐
๐๐2
For a counter-clockwise rotation in Mohrโs circle of 2๐1 + 90deg corresponding to a segment rotation of ๐1 + 45deg = 59.87deg.
Lecture Notes
Introduction to Strength of Materials
pp. 10
Calculated example 7B: Pressure vessel with helical welding
Figure 7-11 The pressure vessel shown is of thickness t=5 mm and radius r=500 mm. The internal pressure is p=20 bar. Calculate a) the stresses in the cylindrical part of the vessel, b) the stresses in the spherical part of the vessel, c) the stress normal to the welding and the shear stress perpendicular to the welding with angle ฮฒ=20 deg. Solution: a) Cylindrical part: the normal stresses are calculated by
๐1 =๐๐
๐ก=
2.0๐
๐๐2โ500 ๐๐
5 ๐๐= 200
๐
๐๐2 (hoop-direction)
๐2 =๐๐
2๐ก=
2.0๐
๐๐2โ500 ๐๐
2โ5 ๐๐= 100
๐
๐๐2 (axial direction)
It is noted that these two stress components are principal stresses and that shear stresses in principal coordinates are 0. b) Spherical part: the normal stresses are calculated by
๐1 = ๐2 =๐๐
2๐ก=
2.0๐
๐๐2โ500 ๐๐
2โ5 ๐๐= 100
๐
๐๐2
The stress distribution in the transition between the spherical and cylindrical part of the pressure vessel is complex and cannot be assessed by simple analytical means. For design purposes, either design rules contained in relevant codes, norms and standards or finite element analysis is applied. c) The stresses in the welding are obtained by rotating the coordinate-system in which stress
calculation is conducted by an angle of ฮฒ (corresponding to an angle of 2ฮฒ in Mohrโs circle), see Figure 7-12-A.
Figure 7-12 Constructing Mohrโs circle for the considered stress state, see Figure 7-12-B., the average stress and the radius are given by
๐๐๐ฃ =๐1+๐2
2=
(100+200)
2
๐
๐๐2 = 150๐
๐๐2
๐ = ๐๐๐๐ฅ =๐๐
4๐ก=
2.0๐
๐๐2โ500 ๐๐
4โ5 ๐๐= 50
๐
๐๐2
Lecture Notes
Introduction to Strength of Materials
pp. 11
[Example 7B continued โฆ] The desired stress components are now obtained by on basis of the relations for right angle triangles and are calculated by
๐๐ค = ๐๐๐ฃ โ ๐ cos(2๐ฝ) = (150 โ 50cos(2 โ 20))๐
๐๐2 = 111.7๐
๐๐2
๐๐ค = ๐ sin(2๐ฝ) = 50 โ sin(2 โ 20)๐
๐๐2 = 32.1๐
๐๐2
Lecture Notes
Introduction to Strength of Materials
pp. 12
Calculated example 7C: stresses in a beam section
Figure 7-13 The cantilever beam shown in Figure 7-13, the length is given by L=5 m, the load by P=50 kN and the moment of inertia Iz=3.67โ108 mm4 based on cross-sectional parameters h=325 mm, b=310 mm, tf=40 mm and tw=20 mm. Calculate a) the maximum normal stress due to bending, b) the maximum shear stress in the cross-section, c) the principal stress in the flange-web junction, d) the von Mises Stress in the flange-web junction Solution a) The applied load can be observed to cause a negative internal bending moment in the beam, so Mmax=-PL. On basis of the flexure formula, we realize that the maximum tensile normal stress due to bending will occur for y=h/2 at the upper face of the beam (since Mz<0). Hence, we obtain
๐๐ฅ,๐๐๐ฅ = โ๐๐ง
โ
2
๐ผ๐ง= โ
โ50โ103Nโ5000mmโ325mm
2
3.67โ108mm4 = 110.7 N/mm2
It is noted, that for the upper face ๐๐ข๐๐๐๐ ๐๐๐๐ = 0.
b) The maximum shear force in the beam is given by Vmax=P and will occur for y=0 along the neutral plane. For the area above the neutral axis, the first order area moment is calculated
by๐ = ๐๐ค๐๐ + ๐๐๐๐๐๐๐ = ((โ
2โ ๐ก๐) ๐ก๐ค)
(โ
2โ๐ก๐)
2+ (๐๐ก๐) (
โ
2โ
๐ก๐
2) = 1.257 โ 106mm3
The shear stress can now be calculated by Grasshofs Formula
๐ =๐๐
๐ผ๐ง๐ก๐ค=
50โ103Nโ1.257โ106mm3
3.67โ108mm4โ15 mm= 17.13 N/mm2
c) The bending stress in the flange-web junction can be obtained by scaling the maximum stress by
๐๐ฅ,๐๐ข๐๐ = ๐๐ฅ,๐๐๐ฅ
โ2 โ ๐ก๐
โ2
= 93.69 N/mm2
The first order area moment of the section considered can be found directly from the calculation in b) and equals the term ๐๐๐๐๐๐๐ = 1.163 โ 106mm3. The shear stress in the
junction is now given by
๐๐๐ข๐๐ =50โ103Nโ1.917โ106mm3
3.67โ108mm4โ15 mm= 15.84 N/mm2
The maximum principal stress is now (for ฯy=0) given by
๐๐๐๐ฅ = ๐๐๐ฃ + ๐ =๐๐ฅ,๐๐ข๐๐
2+ โ(
๐๐ฅ,๐๐ข๐๐
2)
2+ ๐๐๐ข๐๐
2 = 96.3 N/mm2
d) The von Mises stress is (for ฯy=0) given by
๐๐๐๐ = โ๐๐ฅ,๐๐ข๐๐2 + 3๐๐๐ข๐๐
2 = 97.6 N/mm2
Lecture Notes
Introduction to Strength of Materials
pp. 13
Problems
Figure 7.1a- Figure 7.2a Figure 7.1b- Figure 7.2b Problem 7.1 The two pressure vessels shown in Figure 7.1 has thickness t=5 mm and radius r=100 mm. The internal pressure is specified to p=25 bar. Assuming the state of stress plane, a) Calculate the stresses in the directions r1 and r2, b) Calculate the maximum in-plane shear stress in the wall of the pressure vessel, c) Calculate the principal stresses, d) Construct Mohrโs circle for the stress state. Assumining the stress state three dimensional, e) calculate the maximum out-of-plane stress in the pressure vessel Ans: Cylindrical case: a) ฯ1=50 N/mm2, ฯ1=25 N/mm2, b) ฯmax-in-plane=12.5 N/mm2, c) -, d) ฯmax-out-of-plane=25 N/mm2, e) โ Spherical case: a) ฯ1=25 N/mm2, ฯ1=25 N/mm2, b) ฯmax-in-plane=0, c) -, d) ฯmax-out-of-plane=12.5 N/mm2, e) - Problem 7.2 Considering the pressure vessels shown in Figure 7.2 with geometry given in problem 7.1, calculate the maximum internal pressure that can be allowed, if the nominal normal stress is not to exceed 150 N/mm2 in each of the principal directions. Ans: Cylindrical case: stress in direction 1: pallow=7.5 N/mm2, stress in direction 2: pallow=15 N/mm2 Spherical case: stress in direction 1 and 2: pallow=15 N/mm2
Figure 7.3-Figure 7.4 Problem 7.3 The pressure vessel shown in figure 7.3 is of radius r=200 mm and thickness t=5 mm. The helical angle of the shown welding is ฮฒ=25 deg. For a maximum allowable normal stress perpendicular to the welding ๐๐ค,๐๐๐๐๐ค =100 N/mm2, determine the maximum nominal internal
pressure the vessel can sustain Ans: p<4.24 N/mm2
Lecture Notes
Introduction to Strength of Materials
pp. 14
Problem 7.4 The pressure vessel shown in figure 7.3 is of radius r=200 mm and thickness t=5 mm. The helical angle of the shown welding is ฮฒ=25 deg. For a maximum allowable shear stress ๐๐ค,๐๐๐๐๐ค
=25 N/mm2, determine the maximum nominal internal pressure the vessel can sustain Ans: p<3.26 N/mm2
Figure 7.5 Figure 7.6 Problem 7.5 For the plane stress segment shown above, the stress components are given by ฯx=50 N/mm2, ฯy=60 N/mm2 and ฯxy=30 N/mm2. Calculate a) the principal stresses, b) the corresponding angle of rotation, d) Furthermore, draw Mohrโs circle for the stress state shown, c) calculate the maximum shear stress. Ans: a) ฯ1=85.40 N/mm2, ฯ2=24. 59 N/mm2, b) ฮธ1=40.27 deg, ฯmax=30.41 N/mm2 Problem 7.6 For the two stress states shown in Figure 7.6, the stress components are given by ๐๐ฅ,๐ด =
0, ๐๐ฆ,๐ด = 0, ๐๐ฅ๐ฆ,๐ด = 95 N/mm2 with ฮฒ=45 deg. and ๐๐ฅ,๐ต = 44 N/mm2, ๐๐ฆ,๐ต = 88 N/
mm2 , ๐๐ฅ๐ฆ,๐ต = 35 N/mm2. a) Determine the resultant stress state obtained by superposition of
A and B, b) For the resultant stress state, determine the principal stresses and the angle of rotation required to obtain the principal axes. Ans: a) ๐๐ฅ = 139 N/mm2, ๐๐ฆ = โ7 N/mm2, ๐๐ฅ๐ฆ = 35 N/mm2
b) ๐1 = 146.96 N/mm2, ๐2 = โ14.96 N/mm2, ๐1 = 12.8 deg , ๐1 = 102.8 deg