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Effect of Bauschinger Effect and

Yield Criterion on Residual Stress


Distribution of Autofrettaged Tube
X. P Huang
School of Naval Architecture, Many analytical and numerical solutions for determining the residual stress distribution
Ocean and Civil Engineering, in autofrettaged tube have been reported. The significance of the choice of yield criterion,
Shanghai Jiao Tong University, the Bauschinger effect, strain hardening, and the end conditions on the predicted residual
Shanghai 200030, stress distribution has been discussed by many authors. There are some different auto-
China frettage models based on different simplified material strain-hardening behaviors, such
e-mail: xphuang@sjtu.edu.cn as a linear strain-hardening model, power strain-hardening model, etc. Those models
give more accurate predictions than that of elasticperfectly plastic model, and each of
W. C. Cui them suits different strain-hardening materials. In this paper, an autofrettage model con-
China Ship Scientific Research Center, sidering the material strain-hardening relationship and the Bauschinger effect, based on
P.O. Box 116, Wuxi, the actual tensile-compressive stress-strain curve of material, plane-strain, and modified
Jiangsu, 214082, yield criterion, has been proposed. The predicted residual stress distributions of auto-
China frettaged tubes from the present model are compared to the numerical results and the
e-mail: wccui@sjtu.edu.cn experimental data. The predicted residual stresses are in good agreement with the ex-
perimental data and numerical predictions. The effect of Bauschinger effect and yield
criterion on residual stress is discussed based on the present model. To predict residual
stress distribution accurately, it is necessary to properly model yield criterion, Bausch-
inger effect, and appropriate end conditions. DOI: 10.1115/1.2172621

Keywords: autofrettage, residual stress distribution, Bauschinger effect, yield criterion

Introduction perimental work and associated curve-fitting 14,15, a nonlinear


kinematic hardening fit to both loading and unloading profiles is
The autofrettage process is a practical method for increasing the
proposed; the latter also represents unloading as a function of
elastic-carrying capacity and the fatigue life of a thick-walled
prior plastic strain. This work shows that Kendalls fit 11 is
tube, such as a cannon or a high-pressure tubular reactor, etc. The
appropriate to A723-type steels, but that other candidate pressure
essence of the autofrettage technique is the introduction and utili-
vessel steels exhibit significantly different profiles. Associated
zation of residual stresses. These residual stresses are generated
work 16 indicates the crucial importance of end conditions e.g.,
after pressurization causes yielding partway through the tube wall. plane stress, plane-strain, and open-end conditions in analyzing
The reliable prediction of the influence of residual stresses on the the autofrettage process.
elastic-carrying capacity, fatigue crack growth, and fracture in a In this paper, a general autofrettage model considering the ma-
thick-walled tube requires accurate estimation of the residual terial strain-hardening relationship and the effect of Bauschinger
stress field 1. Residual stress distributions can be determined by effect, based on the actual tensile-compressive curve of material
experiments or calculations. The calculation procedures usually and the modified yield criterion and plane strain, incompressible
involve making simplifying assumptions about the material be- material, is proposed. Based on this model, the effect of Bausch-
havior which may limit their accuracies 2. The basic autofrettage inger effect and yield criteria on residual stress distribution are
model proposed by Hill 3 is elastic perfectly plastic. Because of discussed.
the Bauschinger effect and strain hardening, most materials do not
satisfy the elasticperfectly plastic assumption, and consequently,
alternative autofrettage models, based on various simplified mate-
rial strain-hardening characteristics, have been proposed 4. Theoretical Analysis
These are the unloading linear strain-hardening 5, bilinear Material Stress-Strain Relationship. A general material
strain-hardening 6,7, loading elasticperfectly plastic and un- tensile-compressive stress-strain curve is shown in Fig. 1. The
loading power strain-hardening 7,8, loading and unloading curve can be divided into four segments, O-A, A-B, B-D, and DE,
power strain-hardening 9, and loading linear and unloading and be expressed by four equations.
power strain-hardening 10 models. These models give more ac-
curate solutions than the elasticperfectly plastic model, and each 1. Loading phase O-A-B: in the Cartesian coordinate system
of them suits different strain-hardening materials. Kendall 11 O, shown in Fig. 1. An initial tensile loading regime,
proposed a quadratic fit to the Bauschinger-unloading profile. This O-A, during which the steel behaves elastically up to the
fit is a function of prior plastic strain and is based on the work of yield point ss, the elastic modulus over this range is E1.
Milligan et al. 12. It was also the basis of 13 in which several The material then behaves plastically, A-B. This phase may
Tresca, plane stress solutions are presented. In later extensive ex- involve significant nonlinearity. The relationship of stress
and strain can be expressed as
Linear elastic regime O-A
Contributed by the Pressure Vessels and Piping Division of ASME for publication
in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received November 10, = E 1 s 1
2005; final manuscript received November 22, 2005. Review conducted by Anthony
Parker. Paper presented at the Gun Tubes Conference 2005, April 1014, 2005, Strain-hardening regime A-B
Keble College Oxford, hosted by Cranfield University, RMCS, Shrivenham, SN6
8LA. = A 1 + A 2 B1 s 2

212 / Vol. 128, MAY 2006 Copyright 2006 by ASME Transactions of the ASME

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Fig. 2 Radii of elastic plastic zones

+ r + z = 0 7
3. Plane-strain assumption with closed ends
z = 0 8
Fig. 1 General material tensile-compressive stress-strain Yield Criterion. The experiments have shown that von Mises
curve yield criterion and Tresca yield criterion are more suitable for the
elastic-plastic analysis of thick-walled tubes than other yield cri-
teria 5. Stacey and Webster 2 found that close agreement with
2. Unloading phase B-D-E: in the Cartesian coordinate system
experiment is achieved when the unloading stress-strain behavior
*B*, shown in Fig. 1, unloading elastic regime, B-D,
of the material is modeled accurately and the average of the
during which the steel behaves elastically up to the yield Tresca and von Mises yield criteria is used 1. Some researchers
point Es*, the elastic modulus over this range is E2. The have suggested that adopting von Mises yield criteria will give a
material then behaves plastically, D-E. This phase behaves more accurate solution than that of Tresca. The yield criterion can
significant nonlinearity. The relationship of stress and strain be rewritten as the unified form as
can be expressed as 3
Elastic regime B-D i = 2 s 9
= E 2
* *

*
s* 3 where = 1, = 2 / 3, and 1 2 / 3, for Tresca, von Mises,
Strain hardening regime D-E and modified yield criterion, will give.

* = A3 + A4*B2 * s* 4 Residual Stress Distribution. Loading and unloading stress


analysis is performed in the Cartesian coordinate system O and
Fundamental Assumptions
*B* shown in Fig. 1, respectively. The radii of elastic plastic
1. Unique curve assumption The relationship between equiva- zones in the tube wall were shown in Fig. 2. The residual stress
lent strain strain intensity i and equivalent stress stress distribution can be determined by using loading stress minus cor-
intensity i under complex stress states is the same as the responding unloading stress, i.e., R = *. The residual stress
strain-stress relationship under uniaxial tensile-compressive calculation should be expressed in two different cases and three
loading, i.e., Eqs. 14 remain valid when , * , * is zones, respectively.
replaced by i , i* , *. Ideal Elastic Unloading. Loading elastic zone rc r ro
Stress intensity i


s 2 1 1 r2o
i = 21 r2 + r z2 + z 2
pa
5 rR = rc 2 2 2 2 ri2 1 2
2 ro r ro ri r


Strain intensity i 10
s 2 1 1 pa r2o
R rc 2 + 2 2 2 ri2 1 + 2
i =
2
3
r2 + r z2 + z 2 6
=
2 ro r ro ri r
2. Incompressible material assumption Loading plastic zone ri r rc



r s A1 2B1 1 1 pa ri2
rR = 2A1 ln + r r2o 1
B1 c ri2B1 r2B1 r2o ri2 r2


2 ri


11
r s A1 2B1 1 1 pa ri2
R = 2 ln + 1 A1 + r + 2B1 1 2B r2o 1+ 2
2 ri B1 c ri2B1 r 1 r2o ri2 r

Elastic Plastic Unloading. Loading elastic zone and unloading elastic zone rc r ro



1 1
rR = sr2c Er2d 2 2
2 ro r


12
1 1
R = sr2c Er2d 2 + 2
2 ro r

Loading plastic zone and unloading elastic zone rd r rc

Journal of Pressure Vessel Technology MAY 2006, Vol. 128 / 213

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r s A1 2B1 1 1 E 2 1 ri2
rR = 2A1 ln + rc 2B1 2B1 r pa
2 d r2o r2


2 ri B1 ri r


13
r s A1 2B1 1 1 E 2 1 1
R = 2 ln + 1 A1 + r + 2B1 1 2B r + pa
2 ri B1 c ri2B1 r 1 2 d r2o r2
Loading plastic zone and unloading plastic zone ri r rd



r s A1 2B1 1 1 E A3 2B2 1 1
rR = 2A1 A3ln + r rd
B1 c ri2B1 r2B1 ri2B2 r2B2


2 ri B2


14
r s A1 2B1 1 1 E A3 2B2 1 1
R = 2 ln + 1 A1 A3 + r + 2B1 1 2B rd + 2B2 1 2B
2 ri B1 c ri2B1 r 1 B2 ri2B2 r 2

Autofrettage Pressure Discussion


The relationship of pa rc


Effect of Bauschinger Effect on Residual Stress. For suffi-
rc s A1 rc 2B1
rc 2 ciently thick tubes and depths of yielding during the autofrettage
pa = 2A1 ln + 1 S 1 process, reverse yielding may take place adjacent to the inner
2 ri B1 ri ro surface when the internal pressure is removed. For a yield stress in
15 compression equal to that in tension, reyielding occurs when
The relationship of pa rd ro / ri 2.22. It can take place at lower k values due to the Bausch-


inger effect. In general, Bauschinger effect coefficient bef is found
rd E A3 rd 2B2
rd 2
to be material dependent and sensitive to the amount of prior
pa = 2A1 ln + 1 E 1 plastic strain. Typical values of bef in the range 0.31.0 have been
2 ri B2 ri ro
measured 12. The greater the previous plastic strain the smaller
16 the Bauschinger effect coefficient is. The smaller Bauschinger ef-
Critical autofrettage pressure fect coefficient causes the reverse yielding to take place more
The critical autofrettage pressure is defined as the autofrettage easily and affects the residual stress distribution.
pressure when the reverse yield just takes place at the inner sur- In the present model, the effect of Bauschinger effect is consid-
face of the autofrettaged tube. Replace rd with ri in Eq. 16, the ered by parameter E.
critical autofrettage pressure is
E = A1 + A2b1 + befs 18
pacr =
E
2

1
ri
ro
2
17 The effect of Bauschinger effect on residual stress is illustrated in
Fig. 6. The smaller the bef, the larger the reversed yielding radius
is and the less compressive the hoop residual stress is near the
bore. Plastic strain through the wall thickness is not constant; thus,
in reality bef varies with radius. In this analysis, bef was set prag-
Validations matically and the parameter E was determined by stress-strain
Experimental Validation. The experimental material of the
specimen is 30CrNiMo8. The tensile-compressive stress-strain
curve of the material is shown in Fig. 3. The parameters needed in
the present model were determined by fitting the tensile-
compressive stress-strain curve using Eqs. 14 and are listed in
Table 1. The dots shown in Fig. 3 are determined by Eqs. 14
using the data in Table 1. It shows that Eqs. 14 fit the strss-
strain curve well. There is a small difference at the two knots of
the elasticity and plasticity of the stress-strain curve. To eliminate
the difference, parameters s and E should be correspond to the
values of intersection of Eqs. 1 and 2 and Eqs. 3 and 4,
respectively. The internal and external radii, autofrettage pressure,
and some important results are listed in Table 2. The predicted
residual stress distributions and the experimental data measured
by Sachs boring method are shown in Fig. 4. This figure shows
that the calculated elasto-plastic radius is a little smaller than the
measured value when = 1.11, and the predicted residual stresses
are in good agreement with test data.
Numerical Validation. The residual stress distributions pre-
dicted by the present model for 30CrNiMo8 may be compared to
some numerical results of Parker 17 that are shown in Fig. 5.
Parkers results are for A723 steel of the same yield strength and
include Bauschinger effect that varies as a function of plastic
strain and, hence, radius as defined in Ref. 14. There is some
difference between the various results near the bore. To under-
stand these differences now consider some important parameters
affecting residual stress distribution. Fig. 3 Stress-strain curve of 30CrNiMo8

214 / Vol. 128, MAY 2006 Transactions of the ASME

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Table 1 Calculation parameters of 30CrNiMo8

s E1 A1 A2 E E2 A3 A4
MPa MPa MPa MPa B1 MPa MPa MPa Mpa B2 bef

960.7 207000 928.1 7026 1.0 1420 201000 5.0 10850 0.405 0.47

curve fitting in this model. For simulating the stress-strain rela- Effect of Yield Criterion on Residual Stress. The effect of
tionship of the tube under autofrettage pressure with the uniaxial yield criterion on residual stress under same Pa is shown in Fig. 7.
tensile-compressive curve of the material, the maximum strain of The yield radius using Tresca yield criterion is larger than that
the curve should be approximately equal to or less than the von using the von Mises yield criterion, but both criteria give a similar
Mises equivalent strain at the inner surface of the tube under value of residual stress at the bore under the same autofrettage
autofrettage pressure. pressure.
The effect of yield criterion on residual stress under same rc is
shown in Fig. 8. Larger residual stresses are given by using von
Table 2 Radii and autofrettage pressure of the tube: Mises criterion under same rc. Some experimental results indicate
rcc-calculation value; rcm-experimental measuring value that a proper value of the yield criterion parameter will properly
model different conditions. In the present paper, = 1.11 is proper
ri ro pa pacr rcc rcm rd for giving more accurate prediction of residual stress.
mm mm MPa MPa mm mm mm

19.3 43.7 1.11 740 601.9 29.43 30.2 21.16 Conclusions


A general autofrettage model considering the material strain-
hardening relationship and Bauschinger effect, based on actual
tensile-compressive curve of material, modified yield criterion,
and plane-strain, incompressible conditions, has been proposed.
Experimental results show that the present model has strong
curve-fitting ability, and the predicted residual stresses are in good

Fig. 6 Effect of Bauschinger effect on residual stress


Fig. 4 Comparison of predicted results with test data

Fig. 7 Effect of yield criterion on residual stress under same


Fig. 5 Comparison of predicted results with numerical simu- Pa
lation data

Journal of Pressure Vessel Technology MAY 2006, Vol. 128 / 215

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References
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parameters needed in the present model are determined by fitting 11 Kendall, D. P., 1998, Unpublished discussion of a technical report The
the actual tensile-compressive curve of the material using Eqs. Bauschinger Effect in Autofrettaged TubesA Comparison of Models Includ-
24. Because the Bauschinger effect is material dependent and ing the ASME Code by A. P. Parker, and J. H. Underwood, Technical report
ARCCB-TR-98010, US Army ARDEC, Watervliet, New York.
sensitive to the amount of prior plastic strain, the parameter of the 12 Milligan, R. V., Koo, W. H., and Davidson, T. E., 1966, The Bauschinger
Bauschinger effect should be a function of radius. In this analysis, Effect in a High Strength Steel, J. Basic Eng., 88, pp. 480488.
bef was set pragmatically. The maximum tensile strain of the 13 Parker, A. P., Underwood, J. H., and Kendall, D. P., 1999, Bauschinger Effect
tensile-compressive curve should be approximately equal to or Design Procedures for Autofrettaged Tubes Including Material Removal and
Sachs Method, ASME J. Pressure Vessel Technol., 121, pp. 430437.
less than the equivalent strain at the inner surface of the tube 14 Parker, A. P., Troiano, E., Underwood, J. H., and Mossey, C., 2003, Charac-
under autofrettage pressure. The yield criterion will influence the terization of Steels Using a Revised Kinematic Hardening Model Incorporat-
distribution of residual stress, and an appropriate choice of param- ing Bauschinger Effect, ASME J. Pressure Vessel Technol., 125, pp. 277
eter will suit different conditions. 281.
15 Troiano, E., Parker, A. P., Underwood, J. H., and Mossey, C., 2003, Experi-
mental Data, Numerical Fit and Fatigue Life Calculations Relating to Bausch-
inger Effect in High Strength Armament Steels, ASME J. Pressure Vessel
Acknowledgment Technol., 125, pp. 330334.
16 Parker, A. P., 2001, Autofrettage of Open End TubesPressures, Stresses,
The authors greatly appreciate Professor A. P. Parker, who sup- Strains and Code Comparisons, ASME J. Pressure Vessel Technol., 123, pp.
plied many references and provided some useful suggestions and 271281.
comments to this work. 17 Parker, A. P., private communication.

216 / Vol. 128, MAY 2006 Transactions of the ASME

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