May 16-18, 2018, Minneapolis, MN, USA

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

Piping system of Piping systems

a nuclear power of chemical
plant plant

Gun Barrel
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 4

Stresses in a Thick-Walled Pressurized Cylinder

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

Stresses in thick-wall cylinder. (a) Thin

annulus. (b) Cylindrical volume element.
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 5

Elastic Analysis (Lamé Equations):

Hooke’s Law (stress-strain relations)
Equilibrium Equation

Strain-Displacement Relations
Stress Components under
Internal and External Pressure
(Lamé Equations):

Strain Compatibility Condition

 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 6

Stress Components under Internal Pressure Only

Radial stress distribution Hoop (tangential) stress distribution

Large tensile hoop

stress will initiate
crack and accelerate
crack propagation
and shorten the
service life.
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 7

Hoop Stress, , Distribution in A Single Layer Thick-

Wall Cylinder.
2

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

Hydraulic Autofrettage Process

High pressure (dangerous) and partial

autofrettaged (low efficient and high cost)

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

Double-layer Autofrettage Process

• Two layer cylinder tapered in dimension
so that one can slide into another,
generating prestressed assembly.
• High cost and low improvement

With (right) or without (left) internal

pressure

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

Explosive Autofrettage Process

The large internal pressure, developed after detonation of the explosive, force
the piston to accelerate radially outward at the beginning and then reverse
itself inwardly. The process is hard to control, dangerous and cost.

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

Thermal Autofrettage Process

Stress field is generated due to the
temperature gradient developed
between outer and inner wall of
the cylinder.

Left: Autofrettage elastic-plastic stresses; Middle: Residual stresses;

Right: Overall stresses.
S.M Kamal and U. S. Dixit. Feasibility study of thermal autofrettage process. 5th International & 26th All India Manufacturing Technology, Design and Research
Conference (AIMTDR 2014) December 12th–14th, 2014, IIT Guwahati, Assam, India
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 13

Rotational Autofrettage Process

Large enough angular velocity in a thick-walled cylinder generates centrifugal
force, causing beneficial residual stress which is the prerequisite of the
autofrettage process.

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

Swage Autofrettage Process

Carried out by mechanically pushing a profiled oversized mandrel (or swage)
through a thick-walled cylinder, thereby gradually causing plastic deformation
from one end to the other end to the inner layer by radial interference and
creating a favorable compressive residual hoop stress in the inner layer of the
cylinder.
It requires a significantly lower pressure to drive the mandrel as compared to
the hydraulic method, and is energy efficient and safe.

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

3. Modeling of Swage Autofrettage Process

Case study:
A 105mm cannon barrel, modeled as a thick-walled cylinder, made of
high-pressure vessel steel ASTM A723-1130.

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

Material model (nonlinear kinetic hardening with Bauschinger effect)

for cannon barrel A723, and meshed finite element model for swage
autofrettage process
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 17

Modeling Results (Radial Stress)

Swage on halfway

Swage removed
(residual stress)
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 18

Modeling Results (Hoop Stress)

Swage on halfway

Swage removed
(residual stress)
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 19

Modeling Results (Axial Stress)

Swage on halfway

Swage removed
(residual stress)
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 20

4. Validation by Sachs Boring Technique

Procedure of the Sachs Boring Technique
• Prepare (e.g. smooth and degrease)
the component surface at the strain
gauge locations.
• Glue the strain gauges to the
component and attach the lead wires.
• Align the component to the cutting
machine.
• Bore out or turn down the component
in a series of increments.
• Record the new diameter and strain
gauge readings for each incremental
layer removed.
• Analyze the diameter and strain
gauge data to calculate the residual
stress distribution.

SACHS BORING TECHNIQUE at http://www.veqter.co.uk/residual-stress-measurement/sachs-boring

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 21

Fundamentals of Sachs Boring Techniques

• From the Lamé Equations for elastic stresses in thick-walled cylinders, the change in
stress at the outer surface due to the removal of the material between a and c is given by:
𝒂𝟐 (𝝈𝒓 (𝒓 = 𝒄)) 𝒓𝟐 + 𝒃𝟐
∆𝝈𝜽 𝒓 = 𝒃 = (𝐫 = 𝐛 & 𝐚 = 𝐜)
𝒃𝟐 − 𝒂𝟐 𝒓𝟐
• From the general elastic stress-strain relationship:
𝑬 ′𝜽
∆𝝈𝜽 𝒓 = 𝒃 = 𝜺𝜽 + 𝝊𝜺 𝒛 𝒓 = 𝒃 = 𝑬
𝟏 − 𝝊𝟐
• Combining these equations yields:
′
𝒃𝟐 − 𝒄𝟐
𝝈𝒓 𝒓 = 𝒄 = 𝑬 𝜽
𝟐𝒄𝟐
𝒅𝜽 𝒇𝒃 +𝒇
𝝈𝜽 𝒓 = 𝒄 =𝑬′ 𝒇𝒃 − 𝒇 − 𝜽
𝒅𝒇 𝟐𝒇
𝒅𝝀
𝝈𝒛 𝒓 = 𝒄 =𝑬′ 𝒇𝒃 − 𝒇 −𝝀
𝒅𝒇
Where:
𝑬
𝑬′ = ; 𝜽 = 𝜺𝜽 + 𝝊𝜺𝒛 ; 𝝀 = 𝜺𝒛 + 𝝊𝜺𝜽
𝟏 − 𝝊𝟐
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 22

A typical AISI4340 steel tensile-

compression stress-strain curves

1.5E+9

1.0E+9 True stress-strain of 4340

0.2% offset
Reverse loading at 1%
Reverse loading at 2%
True Stress (Pa) 5.0E+8 Reverse loading at 3%
Reverse loading at 4%

Modeling used AISI4340 steel 0.0E+0

-0.010 0.000 0.010 0.020 0.030 0.040
tensile-compression stress-strain True Strain
curves fitted with 0.2% offset -5.0E+8
yield strength curves
-1.0E+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

Residual Stresses (Pa)

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 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

Residual Stresses (Pa)

Axial Stress
Hoop Stress
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 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

K1.5, FL16.7mm, 6.5% Interference, 5.66% PBE

1.0E+9 Radial Stress

Axial Stress

Residual Stresses (Pa)

Hoop Stress

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

Residual Stresses (Pa)

0.0E+0
0 20 40 60 80 100
Normalized Radial Position (%)
-2.5E+8

-5.0E+8 Radial Stress

Axial Stress
Hoop Stress

-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

Residual Stresses (Pa)

0.0E+0
0 20 40 60 80 100

Normalized Radial Position (%)

-5.0E+8
Radial Stress
Axial Stress
Hoop Stress

-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

Residual Stresses (Pa)

5.0E+8

0.0E+0
0 20 40 60 80 100

-5.0E+8 Normalized Radial Position (%)

-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

Normalized Radial Position (%)

-5.0E+8

-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

5. Validation by Neutron Diffraction Measurements

Schematic of Neutron Diffraction Setup
Testing sample preparation:
Two 10 mm-thick disks with
inner and outer radii of
60mm and 135mm, 78.7mm
and 155mm, respectively, cut
from swage autofrettaged
cannon tubes. The predicted
plastic radii for Disk1 and
Disk2 are 96mm and
114mm, respectively,
corresponding to the radial
interference of 1.445% for
Disk1 and 1.165% for Disk2,
respectively.
The lattice strains were measured with a beam of 3×3mm rectangular spot size in 1 mm
increments from the bore to the outer diameter of the tubes. The neutron beam penetrated all the
way through the steel ring thickness; therefore, the measurements were the average value
throughout the thickness. The residual elastic strains were converted to residual stresses by using
the elastic three-dimensional Hooke’s law, by assuming a plane-stress condition.
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.
A. Stacey, et al. Measurement of residual stresses by neutron diffraction. Journal of Strain Analysis, 20(2)(1985)93-100
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 32

Hoop Stress Change During Ring-Cutting by Modeling

Before ring cutting

After ring cutting

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

Stress Contour Plots After Ring-Cutting by Modeling

Left: Residual radial stress; Right: Residual hoop stress

 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 34

Residual Strain Plots After Ring-Cutting by Modeling

Left: Disk 1; Right: Disk 2

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

Residual Stress Plots After Ring-Cutting by Modeling

Left: Disk 1; Right: Disk 2

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

6. Modeling Comparison between

ANSYS and ABAQUS
Swage Autofrettage Model Dimensions:
• The ram: Length: 1.0 and Outside Radius: 0.666
• The Mandrel: Lead-in Angle 1.5 and Lead-out Angle: 3.0 ;
Length: 2.4 and Length of the Flat: 0.084
• The Tube (with entrance and exit transition): Length: 6.0
Outside Radius: 1.50 and 2.00 and Inside Radius: 1.00 (The ratios of Outside
Radius to the Inside Radius are 1.5 and 2.0, respectively)
• The Radial Interference: 1% and 2%
• The Elements
Tube: 8456 axisymmetric 8-node
quadrilateral elements
Mandrel: 1144 axisymmetric 8-
node quadrilateral elements
Ram: 256 axisymmetric 8-node
quadrilateral elements
Contact: 390 contact elements
Total element number: 10246, and
total node number: 30443
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 37

Residual stresses: Ri = 1, Ro/Ri = 1.5 and Interference = 1%:

ABAQUS ANSYS

Based on the private communication.

 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 38

Residual stresses: Ri = 1, Ro/Ri = 1.5 and Interference = 2%:

ANSYS

ABAQUS

Based on the private communication.

 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 39

7. CONCLUSIONS

• To achieve a reliable modeling, proper material model,

element size and density, incremental deformation
steps, boundary conditions and modeling assumptions
are crucial;
• To achieve a reliable experiment, proper assumptions,
data processing and analysis are critical.
• Comparability between the modeling data and the
experimental data are important.
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 40

ACKNOWLEDGEMENTS

This work was supported by the State of South Dakota and

Mechanical Engineering Department at South Dakota State
University and inspired by the Department of Defense project
(Cooperative Agreement # W15QKN-09-2-0002) by METLAB at
South Dakota State University. Related information provided by
Dr. Anthony P. Parker and computational facility technical support
from the University High Performance Computing Center at South
Dakota State University are gratefully acknowledged.
 Modeling and Validating Residual Stresses in Tick-Walled Cylinders 41

THANK YOU FOR YOUR TIME!