Reduction of the residual stresses in cold expanded thick-walled cylinders by plastic compression

We suppose that in order to maintain high accuracy of holes and to lower residual stresses after cold expansion of thick-walled cylinders, which undergo cross-section plastic deformation, it is necessary to perform axial plastic compression and subsequent cold expansion with small interferences. To test this hypothesis, we studied hoop, radial and axial residual stresses in cylinders made of carbon steel AISI 1050 with hole diameter of 5 mm, outer diameter of 15 mm and length of 30 mm by Sachs method as well as accuracy of expanded holes. It is found that double cold expansion with total interference equal to 5.1% generates hoop residual stresses with largest absolute value equal to 284 MPa and ensures high holes accuracy(IT7). After plastic compression with strain equal to 0.5 and 1% the mentioned stresses reduced to 120 and 75 MPa respectively,and accuracy of the holes reduced as well. Subsequent cold expansion with small interference equal to 0.9% helps to restore holes accuracy(IT7)gained by double cold expansion and ensure that absolute value of hoop residual stresses(177 MPa) is lower compared to double cold expansion.

Simulation on flow, heat transfer and stress characteristics of large-diameter thick-walled gas cylinders in quenching process under different water spray volumes

Cooling strength is one of the important factors affecting microstructure and properties of gas cylinders during quenching process,and reasonable water spray volume can effectively improve the quality of gas cylinders and reduce production costs.To find the optimal water spray parameters,a fluid-solid coupling model with three-phase flow was established in consideration of water-vapor conversion.The inner and outer walls of gas cylinder with the dimensions of d914 mm×38 mm×12000 mm were quenched using multi-nozzle water spray system.The internal pressure,average heat transfer coefficient(have)and stress of the gas cylinder under different water spray volumes during quenching process were studied.Finally,the mathematical model was experimentally verified.The results show that both the internal pressure and have increase along with the increase of spray volume.The internal pressure increases slowly first and then rapidly,but have increases rapidly first and then slowly.To satisfy hardenability of gas cylinders,the minimum spray volume should not be less than 40 m^3/(h·m).The results of stress indicate that water spray quenching will not cause deformation of bottle body in the range of water volume from 40 to 290 m^3/(h·m).

A borehole stability study by newly designed laboratory tests on thick-walled hollow cylinders

At several mineral exploration drilling sites in Australia, weakly consolidated formations mainly consistof sand particles that are poorly bonded by cementing agents such as clay, iron oxide cement or calcite.These formations are being encountered when drilling boreholes to the depth of up to 2 0 0 m. To studythe behaviour of these materials, thick-walled hollow cylinder （TWHC） and solid cylindrical syntheticspecimens were designed and prepared by adding Portland cement and water to sand grains. The effectsof different parameters such as water and cement contents, grain size distribution and mixture curingtime on the characteristics of the samples were studied to identify the mixture closely resembling theformation at the drilling site. The Hoek triaxia! cell was modified to allow the visual monitoring of graindebonding and borehole breakout processes during the laboratory tests. The results showed the significanceof real-time visual monitoring in determining the initiation of the borehole breakout. The sizescaleeffect study on TWHC specimens revealed that with the increasing borehole size, the ductility ofthe specimen decreases, however, the axial and lateral stiffnesses of the TWHC specimen remain unchanged.Under different confining pressures the lateral strain at the initiation point of boreholebreakout is considerably lower in a larger size borehole （2 0 mm） compared to that in a smaller one（10 mm）. Also, it was observed that the level of peak strength increment in TWHC specimens decreaseswith the increasing confining pressure.

Stress analytical solution for plane problem of a double-layered thick-walled cylinder subjected to a type of non-uniform distributed pressure

The stress state around circular openings,such as boreholes,shafts,and tunnels,is usually needed to be evaluated.Solutions for stresses,strains and ultimate bearing capacities of pressurized hollow cylinder are common cases.Stress analytical method for plane problem of a double-layered thick-walled cylinder subjected to a type of non-uniform pressure on the outer surface and uniform radial pressure on the inner surface is given.The power series method of complex function is used.The stress analytical solution is obtained with the assumption that two layers of a cylinder are fully contacted.The distributions of normal and tangential contact stress along the interface,tangential stress on the inner boundary and stresses in the radial direction at θ=0°,45° and 90°,are obtained.An example indicates that,when the elastic modulus of the inner layer of a double-layered thick-walled cylinder is smaller than that of the outer layer,the tangential stress is smaller than that in the corresponding point for a traditional cylinder composed of homogeneous materials.In that way,stress concentration at the inner surface can be alleviated and the stress distribution is more uniform.This is a capable way to enhance the elastic ultimate bearing capacity of thick-walled cylinder.

A Review on Vibration Control of Multiple Cylinders Subjected to FlowInduced Vibrations

The fatigue damage caused by flow-induced vibration(FIV)is one of the major concerns for multiple cylindrical structures in many engineering applications.The FIV suppression is of great importance for the security of many cylindrical structures.Many active and passive control methods have been employed for the vibration suppression of an isolated cylinder undergoing vortex-induced vibrations(VIV).The FIV suppression methods are mainly extended to the multiple cylinders from the vibration control of the isolated cylinder.Due to the mutual interference between the multiple cylinders,the FIV mechanism is more complex than the VIV mechanism,which makes a great challenge for the FIV suppression.Some efforts have been devoted to vibration suppression of multiple cylinder systems undergoing FIV over the past two decades.The control methods,such as helical strakes,splitter plates,control rods and flexible sheets,are not always effective,depending on many influence factors,such as the spacing ratio,the arrangement geometrical shape,the flow velocity and the parameters of the vibration control devices.The FIV response,hydrodynamic features and wake patterns of the multiple cylinders equipped with vibration control devices are reviewed and summarized.The FIV suppression efficiency of the vibration control methods are analyzed and compared considering different influence factors.Further research on the FIV suppression of multiple cylinders is suggested to provide insight for the development of FIV control methods and promote engineering applications of FIV control methods.

Limit analysis of viscoplastic thick-walled cylinder and spherical shell under internal pressure using a strain gradient plasticity theory

Plastic limit load of viscoplastic thick-walled cylinder and spherical shell subjected to internal pressure is investigated analytically using a strain gradient plasticity theory. As a result, the current solutions can capture the size effect at the micron scale. Numerical results show that the smaller the inner radius of the cylinder or spherical shell, the more significant the scale effects. Results also show that the size effect is more evident with increasing strain or strain-rate sensitivity index. The classical plastic-based solutions of the same problems are shown to be a special case of the present solution.

Analysis of dynamic stress intensity factors of thick-walled cylinder under internal impulsive pressure

Dynamic stress intensity factors are evaluated for thick-walled cylinder with a radial edge crack under internal impulsive pressure. Firstly, the equation for stress intensity factors under static uniform pressure is used as the reference case, and then the weight function for a thick-walled cylinder containing a radial edge crack can be worked out. Secondly, the dynamic stresses in uncracked thick-walled cylinders are solved under internal impulsive pressure by using mode shape function method. The solution consists of a quasi-static solution satisfying inhomogeneous boundary conditions and a dynamic solution satisfying homogeneous boundary condi- tions, and the history and distribution of dynamic stresses in thick-walled cylinders are derived in terms of Fourier-Bessel series. Finally, the dynamic stress intensity factor equations for thick-walled cylinder containing a radial edge crack sub- jected to internal impulsive pressure are given by dynamic weight function method. The finite element method is utilized to verify the results of numerical examples, showing the validity and feasibility of the proposed method.

Ringlike failure experiment of thick-walled limestone cylinder specimens in triaxial unloading tests

In order to study the failure of surrounding rock under high in situ stress in deep underground engineering projects, disturbed by excavation unloading, we carried out triaxial unloading experiments using thickwalled cylinder specimens on a TATW-2000 rock servo-controlled triaxial testing machine in a laboratory. The specimens were made of limestone material, taken from Tongshan county, Xuzhou city, Jiangsu province, China. In our experiments, rock deformation and failure behavior was studied through loading and unloading of inner hole pressure of thick-walled cylinder specimens. At first, the axial stress, confining pressure and inner pressure were increased simultaneously to a specified designed state of stress. Then, keeping the axial stress and confining pressure stable, the pressure on the inner hole was decreased until the specimen was fractured. When the inner pressure was released completely but the specimen did not fracture, the confining pressure was decreased subsequently until complete failure occurred. Our experimental results suggest that traces of major circular ringlike fractures with a number of radial cracks often appear in thick cylinder walls. This type of ringlike failure phenomenon, similar to intermittent zonal fracturing characteristics of deep exploitation, has, so far, not been published. Our experimental results show that rock deformation and failure behavior of thick-walled limestone cylinders vary under different stress paths between loading and unloading. Tensile failure and orderly failure surfaces occur under unloading conditions while irregular damaged rock blocks are produced during loading failure. This type of triaxial unloading experiment provides for new research methodology and approach for thorough investigations on intermittent zonal fracturing in deep underground excavations.

WEIGHT FUNCTION FOR STRESS INTENSITY FACTORS IN ROTATING THICK-WALLED CYLINDER

The equation of stress intensity factors（SIF） of internally pressurized thick-walled cylinder was used as the reference case. SIF equation of rotating thick-walled cylinder containing a radial crack along the internal bore was presented in weight function method. The weight function formulas were worked out and can be used for all kinds of depth of cracks, rotating speed, material, size of thick-walled cylinder to calculate the stress intensity factors. The results indicated the validity and effectiveness of these formulas. Meanwhile, the rules of the stress intensity factors in rotating thick-walled cylinder with the change of crack depths and the ratio of outer radius to inner radius were studied. The studies are valuable to engineering application.

Analytical Solution and Simplified Formula for Added Mass of Horizontal and Vertical Motions of Truncated Cylinders Under Earthquake Action

This paper investigates the hydrodynamic characteristics of floating truncated cylinders undergoing horizontal and vertical motions due to earthquake excitations in the finite water depth.The governing equation of the hydrodynamic pressure acting on the cylinder is derived based on the radiation theory with the inviscid and incompressible assumptions.The governing equation is solved by using the method of separating variables and analytical solutions are obtained by assigning reasonable boundary conditions.The analytical result is validated by a numerical model using the exact artificial boundary simulation of the infinite water.The main variation and distribution characteristics of the hydrodynamic pressure acting on the side and bottom of the cylinder are analyzed for different combinations of wide-height and immersion ratios.The added mass coefficient of the cylinder is calculated by integrating the hydrodynamic pressure and simplified formulas are proposed for engineering applications.The calculation results show that the simplified formulas are in good agreement with the analytical solutions.

Numerical evaluation of an autofrettaged thick-walled cylinder under dynamically applied axially non-uniform internal service pressure distribution

A dynamical moving pressure structural numerical calculation model using the internal ballistics calculation pressure-time results was constituted and the vicinity of the internal ballistics and quasiinternal ballistics structural model was checked. The Von Mises stresses obtained by the dynamical structural numerical model calculations and the Von Mises stresses calculated from the shot test strain measurements were compared. The difference for the worse case was 20% and for the best case was 0.1%.Furthermore, the model gave better agreement for the higher charge masses. The numerical structural quasi-internal ballistics computation model created was verified for the top charge mass which represents the highest stress condition and used in a gun barrel design.

THEORY OF THICK-WALLED SHELLS AND ITS APPLICATION IN CYLINDRICAL SHELL

In this paper, a theory of thick-walled shells is established by means of Hellinger-Reissner's variational principle, with displacement and stress assumptions. The displacements are expanded into power series of the thickness coordinate. Only the first four and the first three terms are used for the displacements parallel and normal to the middle surface respectively. The normal extruding and transverse shear stresses are assumed to be cubic polynomials and to satisfy the boundary stress conditions on the outer and inner surfaces of the shell. The governing equations and boundary conditions are derived by means of variational principle. As an example, a thick-walled cylindrical shell is disscussed with the theory proposed. Furthermore, a photoelastic experiment has been carried out, and the results are in fair agreement with the computations.

An approach for optimization of the wall thickness (weight) of a thick-walled cylinder under axially non-uniform internal service pressure distribution

Today, improving the weight/load carrying capacity ratio of a part is the matter of studies in most of the scientific and industrial areas.Autofrettage dimensions, the amount of material removed from outer and inner radius while manufacturing and the service pressure applied affect the residual stress distribution throughout the wall thickness and hence the load-bearing capacity of a thick-walled cylinder. Calculation of residual stresses after autofrettage process and optimization of autofrettage outline dimensions by using the amount of service pressures applied are common issues in literature.In this study, mandrel-cylinder tube interference dimensions were renovated by using traditional methods for swage autofrettage process of a gun barrel. Also, the residual stresses in the cylinder after autofrettage process, inside and outside material removal process and the variable service pressure throughout the cylinder applied were taken into consideration and incorporated into the design. By using the constrained optimization method, wall thickness(thus the weight) was optimized(minimized)to achieve the specified safety factor along the length of the cylinder. For the same cylinder, the results of the suggested analytical/with residual stress calculation approach were compared to analytical/without residual stress calculation results and numerical topology optimization method calculation results. Since the experimental measurement results are not yet available, it was not possible to compare them with the calculation results.The suggested approach enabled 22.9% extra weight reduction in proportion to numerical topology optimization and enabled 4.2% extra weight reduction in proportion to analytical/without residual stress optimization.Using this approach, the gain from residual stresses after autofrettage operation, the loss of residual stresses after material removal, and the effects of service pressures can be taken into account for each stage of design.

Modeling and Simulation of the Characteristics of Pneumatic Cushion Cylinders

The analysis of the characteristics of the cushion process of the pneumatic cushion cylinder is presented, and the nonlinear model of pneumatic cushion cylinders is built in the form of nonlinear differential equations. Besides, through the simulation of the pressure in the cushion chamber, the characteristics of the pneumatic cushion cylinder are obtained, which helps to understand the performance of the pneumatic cushion cylinder and improve or design the better cushion structure.

DRX rules during extrusion process of large-scale thick-walled Inconel 625 pipe by FE method

A thermal-mechanical and micro-macro coupled finite element（FE） model for the hot extrusion process of large-scale thick-walled Inconel 625 pipe was developed based on the DEFORM-2D platform.Then,the influence rules of the key extrusion parameters on the average grain size and grain uniformity of the extruded pipe were revealed.The results show that with the increase of initial billet temperature,extrusion speed and friction coefficient,the grain uniformity is firstly improved and then deteriorated.Larger extrusion ratio leads to more uniform grain distribution.With the increase of initial billet temperature,the average grain size of the pipe first decreases and then increases.Additionally,larger extrusion ratio can bring smaller average grain size.The extrusion speed and friction coefficient have slight effects on the average grain size of the extruded pipe.

Associated rules between microstructure characterization parameters and contact characteristic parameters of two cylinders

The contact strength calculation of two curved rough surfaces is a forefront issue of Hertz contact theory and method. Associated rules between rough surface characterization parameters(correlation length, and root mean square deviation) and contact characteristic parameters(contact area, maximum contact pressure, contact number, and contact width) of two rough cylinders are mainly studied. The contact model of rough cylinders is deduced based on GW model. As there is no analytical solution for the pressure distribution equation, an approximate iterative solution method for the pressure distribution is adopted. Furthermore, the quantitative relationships among the correlation length, the root mean square deviation, the asperity radius of curvature and the asperity density are also obtained based on a numerical simulation method. The maximum contact pressure and the contact number decrease with the increase of correlation length, while the contact width and the contact area are on the contrary. The contact width increases with the increase of root mean square deviation while the maximum contact pressure, the contact area and the contact number decrease.

Scale-adaptive simulation of flow past wavy cylinders at a subcritical Reynolds number

The Xu ＆ Yan scale-adaptive simulation （XYSAS） model is employed to simulate the flows past wavy cylinders at Reynolds number 8 × 10 3.This approach yields results in good agreement with experimental measurements.The mean flow field and near wake vortex structure are replicated and compared with that of a corresponding circular cylinder.The effects of wavelength ratios λ/D m from 3 to 7,together with the amplitude ratios a /D m of 0.091 and 0.25,are fully investigated.Owing to the wavy configuration,a maximum reduction of Strouhal number and root-meansquare （r.m.s） fluctuating lift coefficients are up to 50% and 92%,respectively,which means the vortex induced vibration （VIV） could be effectively alleviated at certain larger values of λ/D m and a /D m.Also,the drag coefficients can be reduced by 30%.It is found that the flow field presents contrary patterns with the increase of λ/D m.The free shear layer becomes much more stable and rolls up into mature vortex only further downstream when λ/D m falls in the range of 5-7.The amplitude ratio a /D m greatly changes the separation line,and subsequently influences the wake structures.

Experimental Study on Ocean Internal Wave Force on Vertical Cylinders in Different Depths

A series of experimental studies about the force of internal solitary wave and internal periodic wave on vertical cylinders have been carried out in a two-dimensional layered internal wave flume. The internal solitary waves are produced by means of gravitational collapse at the layer thickness ratio of 0.2, and the internal periodic waves are produced with rocker-flap wave maker at the layer thickness ratio of 0.93. The wave parameters are obtained through dyeing photography. The vertical cylinders of the same size are arranged in different depths. The horizontal force on each cylinder is measured and the vertical distribution rules are researched. The internal wave heights are changed to study the impact of wave heights on the force. The results show that the horizontal force of concave type internal solitary wave on vertical cylinder in the upper-layer fluid has the same direction as the wave propagating, while it has an opposite direction in the lower-layer. The horizontal force is not evenly distributed in the lower fluid. And the force at different depths increases along with wave height. Internal solitary wave can produce an impact load on the entire pile. The horizontal force of internal periodic waves on the vertical cylinders is periodically changed at the frequency of waves. The direction of the force is opposite in the upper and lower layers, and the value is close. In the upper layer except the depth close to the interface, the force is evenly distributed; but it tends to decrease with the deeper depth in the lower layer. A periodic shear load can be produced on the entire pile by internal periodic waves, and it may cause fatigue damage to structures.

Elastic and viscoelastic solutions to rotating functionally graded hollow and solid cylinders

Analytical solutions to rotating functionally graded hollow and solid long cylinders are developed. Young＇s modulus and material density of the cylinder are assumed to vary exponentially in the radial direction, and Poisson＇s ratio is assumed to be constant. A unified governing equation is derived from the equilibrium equations, compatibility equation, deformation theory of elasticity and the stress-strain relationship. The governing second-order differential equation is solved in terms of a hypergeometric function for the elastic deformation of rotating functionally graded cylinders. Dependence of stresses in the cylinder on the inhomogeneous parameters, geometry and boundary conditions is examined and discussed. The proposed solution is validated by comparing the results for rotating functionally graded hollow and solid cylinders with the results for rotating homogeneous isotropic cylinders. In addition, a viscoelastic solution to the rotating viscoelastic cylinder is presented, and dependence of stresses in hollow and solid cylinders on the time parameter is examined.

Wave-Current Forces on Small Square Cylinders (Part I)

-Based on the extended Morison Equation and model tests, the in-line forces on small square cylinders caused by waves (regular and irregular) and currents are analyzed in detail in this paper. The hydrodynamic coefficient CD and Cu related to KC number and the effect of direction of wave incidence are also given, which can be used in engineering practice.