Inelastic Analysis Approaches for Pressure Vessel Design

HONGJUN LI
Department of Mechanical Engineering

University of Strathclyde
Glasgow, Scotland, UK
FENET THEMATIC NETWORK

COMPETITIVE AND SUSTAINABLE GROWTH
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Introduction
FEA is an established analysis method used in Pressure Vessel Design

• Most DBA is still based on elastic analysis
• Inelastic analysis is becoming more widely used
This presentation will describe new approaches to inelastic design
developed at the University of Strathclyde by
Hongjun Li
Martin Muscat
Bobby Hamilton
Donald Mackenzie
Specifically
• A new criterion of plastic collapse for strain hardening plastic
analysis
• A bounding theorem method for calculating shakedown loads

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INELASTIC FAILURE MODES
¾ Gross plastic deformation under static load

• In elastic DBA, prevented by limiting the elastic primary
stress in the vessel.
• In inelastic DBA calculate permissible load through
inelastic analysis
¾ Incremental plastic collapse (ratchetting)
• In elastic DBA, shakedown is “assured” by limiting the
elastic primary plus secondary stress to twice yield
• In inelastic DBA, calculate permissible load through
inelastic shakedown analysis

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Inelastic Material Models
σ PLASTIC
σ PLASTIC
σY YIELD
σY YIELD
E E
ELASTIC
ELASTIC
ε ε
(a) Non-linear stress-strain (b) Multi-linear isotropic hardening
σ σ
PLASTIC
PLASTIC
σY YIELD EP σY YIELD
E E
ELASTIC ELASTIC
ε ε
(c) Bilinear kinematic hardening (d) Perfect plasticity

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Gross Plastic Deformation
under Static Load

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Types of inelastic analysis
Limit analysis
• Assumes an elastic-perfectly plastic material model and small
deformation theory
• The limit load is the highest load satisfying equilibrium between
external and internal forces
• May be assumed to be the ductile collapse load in DBA.
• The allowable load is two thirds of limit load
¾ “Plastic” analysis
• Strain hardening and large deformation effects may be included
• A criterion of plastic collapse is applied to determine the allowable
load
• The “plastic load” characterises gross plastic deformation
• The allowable load is two thirds of plastic load

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Limit Analysis
Advantages
9 No inelastic stress strain design data needed
9 Load-path independent – don’t need to know load history
9 Conservative if non-linear geometric weakening is not
significant
9 Easier than elastic analysis
Disadvantages
× Not conservative if non-linear geometric weakening is
significant
× Does not account for enhanced strength due to strain
hardening
× Can be difficult to evaluate limit load if solution converges
for unrealistic deformations

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Example: Multilinear Hardening Plastic Analysis

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ASME Criterion of Plastic Collapse
The twice elastic slope Load

criterion (TES)
Applied to PP
characteristic load-
deformation curve
k /2
obtained by plastic
analysis k
D e fo r m a tio n

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Deformation Parameter
∆V
¾ Little guidance on nature and F
location of deformation P
d
parameter given
D. PRESSURISED
CLOSED VESSEL
A. CANTILEVER
¾ Choice can significantly BENDING

w
affect the calculated M

P
plastic load. θ
• Gerdeen proposed the B. MOMENT E. PRESSURE IN

LOADING HEAD
product of the load and w

d
deformation parameters P
should have units of work
P
(Nm) if possible C. PRESSURISED F. PRESSURE IN
CYLINDER NOZZLE

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Problems with the ASME Procedure
The method is heuristic or arbitrary

• Based on experimental experience with specific
configurations
Choice of suitable load and deformation parameters
• Especially for non-proportional combined loading
• In some cases no intersection occurs between the load-
deformation curve and collapse limit line
The plastic load is influenced by the elastic response
• Value of plastic load is dependent on FE modelling
assumptions
Does not adequately represent the effect material strain
hardening has on plastic deformation
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A New Plastic Criterion
¾Based on plastic work concepts P la s tic

¾ The evolution of the gross plastic W o rk
deformation mechanism is
characterised by
S lo p e
¾The rate of change of slope of
the Wp-Q curve, or
L oad
¾The curvature at a point on
the curve 2
d Wp
1 dQ 2
=
ρ ⎡ ⎛ dW p 2
⎤
3
2
⎞
⎢1 + ⎜⎜ ⎟⎟ ⎥
⎢⎣ ⎝ dQ ⎠ ⎥⎦

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Curvature and Gross Plastic Collapse
¾Example: bilinear hardening beam in pure

bending M
¾Post-yield curvature indicates post-yield (Nm) curvature
stress redistribution
¾ Plastic deformation
¾The maximum rate of stress redistribution Discontinuity
corresponds with maximum curvature

¾ Subsequent decrease in curvature
indicates decreasing rate of stress
redistribution Hardening
¾ Minimum or zero curvature indicates Analysis
little or no redistribution
¾ Gross plastic deformation
W P (Nm)

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Curvature and Gross Plastic Collapse
Plastic Work Curvature or PWC M

criterion of plastic load (Nm) curvature
• The load corresponding to

constant or zero curvature Discontinuity
after stress redistribution
Hardening
Analysis
W P (Nm)

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Pipe Bend Example: ASME Approach
1000
900
800
700
Moment-2*kNm
600
500
Closing & perfectly plastic
400 Closing & 5% bilinear
300 Opening & perfectly plastic
Opening & 2% bilinear
200
100
0
0 5 10 15 20 25 30
Rotation -Degree

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Pipe Bend Example: Closing Moment
Moment
kNm Moment
kNm
637.5
720
500 600
Plastic work Plastic work
Perfectly Plastic Bilinear Hardening

MTES= NA MTES=700 kNm
MPWC=637.5 kNm MPWC=720 kNm

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Pipe Bend Example: Opening Moment
Moment
kNm
Moment
kNm
1120
1180
Plastic Work
Plastic Work
Perfectly Plastic Bilinear Hardening

MTES=915 kNm MTES=980 kNm
MPWC=1120 kNm MPWC=1180 kNm

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Shakedown & Ratchetting
under Cyclic Load

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Ductile Failure under Cyclic Loads
• Maximum load between first yield and plastic collapse

• Elastic shakedown
• Plastic shakedown (alternating plasticity)
• Ratchetting
• DBA must ensure shakedown of the vessel

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Elastic Shakedown of Thick Cylinder
P
PS A B
B D
PY
A
C
t
C D

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Preventing Cyclic Failure in PVD
High cycle & low cycle fatigue

• Perform a fatigue analysis
• Establish the design life of the vessel
Ratchetting
• Ensuring that the structure shakes-down to elastic
action

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Shakedown Analysis: Plastic DBA
Incremental elastic-plastic Finite Element Analysis

• Simulate the structural response for a given load history
• Monitor the resulting plastic strain accumulation
• No plastic strain accumulation & No alternating
plasticity: elastic shakedown
• Alternating plasticity: plastic shakedown
• Plastic strain increases with each cycle: ratchetting

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Elastic Shakedown of thick Vessel
Incremental elastic-plastic analysis

ε1p
0
t
P
Py
t
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Plastic Shakedown of Thick Vessel
ε1p
0
t
P
Py

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Ratchetting of Thick Vessel

ε1p
0
t
P
Py
t
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Incremental FEA
Does not predict the specific value of the shakedown load

• Demonstrates the structural response for a given load
level
• A number of simulations at different loads needed to
identify shakedown load
• PV design codes simply require that shakedown is
demonstrated for a specific load
• Can be difficult to distinguish between plastic
shakedown and ratchetting
• Large number of cycles may be needed
• Expensive in computer requirements

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Shakedown Bounding Theorems
Similar approach to (lower bound) limit load analysis

• Establishes a lower bound on the shakedown load for
design purposes
• Does not calculate realistic stress and strain values
• Independent of load history
Melan’s (lower bound) theorem:
• ‘For a given time dependent cyclic load set, a structure
made of elastic-perfectly plastic material will exhibit
shakedown if a constant residual stress field can be
found such that the yield condition is not violated for any
combination of time dependent cyclic elastic stress and
residual stress’.
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Muscat’s Lower Bound Method
The lower bound limit load theorem can be coupled with

FEA to evaluate elastic shakedown loads
Muscat’s method uses static FEA to calculate “elastic” and
“elastic plus residual” stress fields for Melan’s theorem
• Limit analysis is performed with results stored for n load
levels up to the limit load
• “Elastic plus residual” stress is assumed to be the
limit load solution for each load Pn
– Satisfies Melan’s theorem
• “Elastic” stress is the conventional elastic stress at
load Pn

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Applying Melan’s Theorem
Residual stress calculated by superposition of “Elastic

plus residual” and “Elastic” stress fields
• Residual stress = (Elastic Plus Residual)- (Elastic)
Load Pn is a lower bound on the shakedown load if

• Maximum residual stress is less than yield
• Maximum “Elastic plus residual” stress is less than
yield

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Shakedown of a Thick Cylinder
Calculate stress fields

by limit analysis for
load Pn
Elastic plus Residual Stress: Elastic Stress:

from limit analysis From scaled initial elastic response
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Calculate residual
stress field for load Pn
-
(Elastic plus residual) – (Elastic) Stress
= Residual Stress

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Apply Melan’s Theorem
-
(Elastic plus residual) ≤ σy: Yes
(Residual) ≤ σy: Yes

Pn is a lower bound shakedown load
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Conclusion: Inelastic Analysis in PV DBA
Inelastic analysis allows allowable loads to be calculated

by simulating inelastic response
• Limit analysis, Limit load
• Plastic analysis, Plastic load
• A criterion for plastic collapse is required for gross
plastic deformation design in plastic analysis
• Problems with TES
• The Plastic Work Curvature criterion is a consistent
and robust criterion which accounts for the effects of
geometric non-linearity and strain hardening

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Shakedown can be assessed through
• Performing incremental elastic plastic analysis and
monitoring plastic strain accumulation over a number
of cycles
• Applying a lower bound theorem based approach
such as Muscat’s Method to the results of a (static)
limit analysis
– Requires only a single limit analysis
– Clearly establishes the elastic shakedown load

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I would like thank Dr Mackenzie for his help during the
preparation of this presentation!
QUESTIONS?

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Inelastic Analysis Approaches for Pressure Vessel Design

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HONGJUN LI

Department of Mechanical Engineering

FENET THEMATIC NETWORK

 FEA is an established analysis method used in Pressure Vessel Design

FENET THEMATIC NETWORK

¾ Gross plastic deformation under static load

FENET THEMATIC NETWORK

FENET THEMATIC NETWORK

FENET THEMATIC NETWORK

FENET THEMATIC NETWORK

FENET THEMATIC NETWORK

FENET THEMATIC NETWORK

 The twice elastic slope Load

FENET THEMATIC NETWORK

¾ Choice can significantly BENDING

affect the calculated M

• Gerdeen proposed the B. MOMENT E. PRESSURE IN

product of the load and w

FENET THEMATIC NETWORK

The method is heuristic or arbitrary

¾Based on plastic work concepts P la s tic

FENET THEMATIC NETWORK

¾Example: bilinear hardening beam in pure

corresponds with maximum curvature

FENET THEMATIC NETWORK

 Plastic Work Curvature or PWC M

• The load corresponding to

after stress redistribution

FENET THEMATIC NETWORK

FENET THEMATIC NETWORK

Plastic work Plastic work

Perfectly Plastic Bilinear Hardening

FENET THEMATIC NETWORK

Perfectly Plastic Bilinear Hardening

MPWC=1120 kNm MPWC=1180 kNm

FENET THEMATIC NETWORK

FENET THEMATIC NETWORK

• Maximum load between first yield and plastic collapse

FENET THEMATIC NETWORK

FENET THEMATIC NETWORK

 High cycle & low cycle fatigue

FENET THEMATIC NETWORK

 Incremental elastic-plastic Finite Element Analysis

FENET THEMATIC NETWORK

 Incremental elastic-plastic analysis

 Incremental elastic-plastic analysis

FENET THEMATIC NETWORK

 Incremental elastic-plastic analysis

 Does not predict the specific value of the shakedown load

FENET THEMATIC NETWORK

 Similar approach to (lower bound) limit load analysis

 The lower bound limit load theorem can be coupled with

FENET THEMATIC NETWORK

 Residual stress calculated by superposition of “Elastic

 Load Pn is a lower bound on the shakedown load if

FENET THEMATIC NETWORK

Calculate stress fields

Elastic plus Residual Stress: Elastic Stress:

(Elastic plus residual) – (Elastic) Stress

FENET THEMATIC NETWORK

(Elastic plus residual) ≤ σy: Yes

(Residual) ≤ σy: Yes

FEA is an established analysis method used in Pressure Vessel Design

The twice elastic slope Load

The method is heuristic or arbitrary

Plastic Work Curvature or PWC M

High cycle & low cycle fatigue

Incremental elastic-plastic Finite Element Analysis

Incremental elastic-plastic analysis

Incremental elastic-plastic analysis

Incremental elastic-plastic analysis

Does not predict the specific value of the shakedown load

Similar approach to (lower bound) limit load analysis

The lower bound limit load theorem can be coupled with

Residual stress calculated by superposition of “Elastic

Load Pn is a lower bound on the shakedown load if

Inelastic analysis allows allowable loads to be calculated