A three-dimensional finite-element method computer program was developed to establish the elastic—plastic, residual, and service stress distributions in cylinders with flush and non-protruding optimal-chamfered cross-bores under internal pressure. Eight-noded brick and four-noded tetrahedral isoparametric elements and the displacement formulation were used. The incremental theory of plasticity with a 5 per cent yield condition and von Mises yield criterion were assumed. The incipient and 5 per cent overstrain (ov) pressures were established for various thickness ratios and cross-bore to main bore radius ratios. For the optimum chamfer angle geometrical configuration, the stresses were determined for varying ov. The maximum and minimum effective stresses were located 7.5° from the meridional and transverse planes, respectively. Meridional plane through thickness yielding occurred at an ov of 41 per cent. The service stress gradients at the cross-bore chamfer end increased with ov for ovs >30 per cent. Stress reversals were eliminated for overstrain >27 per cent. Alternative autofrettage and yield condition procedures were proposed.
BushS. H.Statistics of pressure vessel and piping failures. J. Press. Vessel Technol., 1988, 110, 225–233.
3.
IwadateT.ChibaK.WatanabeJ.MimaS.TokaiK.TakedoH.Safety analysis at a cross bore corner of high pressure polyethylene reactors. International Conference of Pressure Vessels and Piping: Materials, Nuclear Engineering and Solar Energy. Trans. ASME, 1981, 103, 117–125.
4.
MasuL. M.The effect of cross bore geometry on the strength of pressure vessels., PhD Thesis, University of Leeds, 1989.
5.
KihiuJ. M.Numerical stress characterization in cross-bored thick walled cylinders under internal pressure. PhD Thesis, University of Nairobi, 2002.
6.
FordH.WatsonE. H.CrosslandB.Thoughts on a code of practice for forged high pressure vessels of monobloc design. Trans. ASME, 1981, 103, 2–8.
7.
FaupelJ. H.HarrisB.Stress concentrations in heavy walled cylindrical pressure vessels. J. Ind. Eng. Chem., 1957, 49, 1979–1986.
8.
FaupelJ. H.Yield and bursting characteristics of heavy-wall cylinders. Trans. ASME, 1956, 78 (5), 1031–1064.
9.
DaviesL. M.GarneL.CollierJ. G.Second marshall study group on PWR pressure vessel integrity. J. Press. Vessel Technol., 1983, 105, 53–57.
10.
KihiuJ. M.MutuliS. M.RadingG. O.Stress characterization in autofrettaged thick walled cylinders. Int. J. Mech. Eng. Education. University of Manchester, 2003, 31 (4), 370–389.
11.
JorgensenS. M.Overstrain tests on thick walled cylinders. J. Eng. Ind., 1960, 82, 103–121.
12.
FaupelJ. H.FurbeckA. R.Influence of residual stresses on behaviour of thick walled closed-end cylinders. In Proceedings of the 7th National Instruments Conference, Cleveland, Ohio, 9–10 September 1952.
13.
LéN. V.Method and mechanism of beneficial residual stresses in tubes. J. Press. Vessel Technol., 1994, 116, 175–178.
14.
MarcalP. V.A stiffness method for elastic-plastic problems. Int. J. Mech. Sci., 1965, 7, 220–238.
15.
YamadaY.YashimuraN.SakuraiT.Plastic stress-strain matrix and its application for the solution of elastic-plastic problems by the finite element method. Int. J. Mech. Sci., 1968, 10, 343–354.
16.
OwenD. R. J.SalonenE. M.Three dimensional elastic-plastic finite element analysis. Int. J. Num. Meth. Eng., 1975, 9, 209–218.
17.
TomitaY.ShindoA.NagaiM.Axisymmetric deformation of circular elastic-plastic tubes under axial tension and internal pressure. Int. J. Mech. Sci., 1984, 26(6–8), 437–444.
18.
PillingerI.HartleyP.SturgessC. E. N.RoweG. W.Use of mean normal technique for efficient and numerically stable large strain elastic-plastic finite element solutions. Int. J. Mech. Sci., 1986, 28 (1), 23–29.
MasuL. M.Plasticity analysis and cross bore size effects on the fatigue strength of thick walled cylinders. E. Afr. J. Eng., 1994, 1 (2), 22–23.
21.
TanC. L.Stress distributions in thick walled cylinders due to the introduction of bore after autofrettage. J. Strain Analysis, 1986, 21, 177–183.
22.
JorgensenS. M.Overstrain and bursting strength of thick-walled cylinders. Trans. ASME, 1958, 80 (3), 561–570.
23.
DudansZ.Finite element incremental elastic-plastic analysis in pressure vessels. J. Eng. Ind., 1970, 92, 293–302.
24.
HsuL. C.Analysis for design. Part 1. Introduction: Pressure vessels and piping: Design and analysis. Vol. 1. Analysis, 1972, (ASME, United Engineering Centre, New York).
25.
HussainM. A.PuS. L.VasilakisJ. D.O'HaraP.Simulation of partial autofrettage by thermal loads. J. Press. Vessel Technol., 1980, 102, 314–318.
26.
ZhouH.RaoM. D.On the error analysis of residual stress measurements by the hole drilling method. J. Strain Analysis, 1993, 28 (4), 273–276.
27.
SharmanD. J.StarkH. L.KellyD. W.Bench marking of a destructive technique to determine residual stresses in thick walled axisymmetric components. J. Strain Analysis, 1997, 32 (2), 87–96.
28.
SharmanD. J.StarkH. L.KellyD. W.A comparison of potential methods for the alleviation of residual stresses in the necks of aluminium alloy thick-walled gas cylinders. J. Strain Analysis, 1997, 32 (5), 315–323.
29.
PerlM.AronéR.An axisymmetric stress release method for measuring the autofrettage level in thick-walled cylinders - part I: Basic concept and numerical simulation. J. Press. Vessel Technol., 1994, 116, 384–388.
30.
ChenP. C. T.The Bauschinger and hardening effects on residual stresses in an autofrettaged thick walled cylinder. J. Press. Vessel Technol., 1986, 108, 109–112.
31.
ReesD. W. A.Autofrettage theory and fatigue life of open ended cylinders. J. Strain Analysis, 1990, 25 (2), 109–121.
32.
JahedH.DubeyR. N.An axisymmetric method of elastic-plastic analysis capable of predicting residual stress field. J. Press. Vessel Technol., 1997, 119, 264–273.
33.
KihiuJ. M.MutuliS. M.Time and space management in structural analysis problems. Int. J. Mech. Eng. Edu., 1998, 26 (4), 273–292.
34.
KihiuJ. M.RadingG. O.MutuliS. M.Geometric constants in plain cross-bored cylinders. J. Press. Vessel Technol., 2003, 125, 446–453.
35.
KihiuJ. M.RadingG. O.MutuliS. M.Overstraining in flush plain cross-bored cylinders. Proc. Instn Mech. Engrs. Part C: J. Mechanical Engineering Science, 2004, 218(C2), 143–153.
36.
KihiuJ. M.RadingG. O.MutuliS. M.Transition, convergence and constancy in radiused entry cross-bored cylinders. Trans. Can. Soc. Mechanical Engineers, 2004, 28(2B), 343–353.
37.
KihiuJ. M.RadingG. O.MutuliS. M.Overstrain in flush radiused entry cross-bored cylinders. J. Strain Analysis, 2005, submitted for publication.
38.
KihiuJ. M.RadingG. O.MutuliS. M.Universal SCFs in optimal chamfered cross-bored cylinders. Int. J. Press. Vessels Piping, 2005, submitted for publication.
39.
MrazG. J.NisbettE. G.Design, manufacture and safety aspects of forged vessels for high pressure service. J. Press. Vessel Technol., 1980, 102, 99–106.
HintonE.CampbellJ. S.Local and global smoothing of discontinuous finite element function using a least square method. Int. J. Num. Meth. Eng., 1974, 8, 461–480.
