DESIGN AND ANALYSIS OF EXPANSION JOINTS AND BELLOWS€¦ · DESIGN AND ANALYSIS OF EXPANSION JOINTS...

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DOI:10.23883/IJRTER.2018.4149.QLJI6 430 DESIGN AND ANALYSIS OF EXPANSION JOINTS AND BELLOWS S.VARUNRAJ 1 , SUDHARSAN.K 2 1 assistant Professor, Mechanical Department, Vels Institute Of Science, Technology And Advanced Studies, Pallavaram, Chennai-117 2 assistant Professor, Mechanical Department, Velammal Engineering College, Velammal Nagar, Ambattur-Red Hills Road, Chennai - 600 066. Abstract: An Expansion Joints is an assembly designed to absorb the expansion and contraction of various construction materials, to absorb vibration, or to allow movement due to ground settlement or earthquakes. An Expansion joint refers to a metal bellows expansion joint designed to absorb axial, lateral and angular motions in piping system. The bellows is the flexible element of the expansion joint. It must be strong enough circumferentially to withstand the pressure and flexible enough longitudinally to accept the deflections for which it was designed, and as repetitively as necessary with a minimum resistance. This strength with flexibility is a unique design problem that is not often found in other components in industrial equipment. Since the bellows must accept deflections repetitively, and deflections result in stresses, these stresses must be kept as low as possible so that the repeated deflections will not result in premature fatigue failures. In this project a metal expansion joint along with the bellows and the entire pipe cross over and the pressure parts in the cross over is designed by considering above words while designing. In the cross over “In line Pressure Balanced Expansion Joint” is replaced instead of Single Expansion Joints and Elbow Pressure Balanced Expansion Joints is also present in the cross over. Pressure is applied in the cross over. Design calculation is done manually. Then the design is modeled in the software Inventor. Then the model is imported by converting it in to STEP file format to the software Hyper Works. Finite Element Analysis is continued in the software Hyper Mesh and the results are compared with the manual results. Based on the results, suggestions are given to the industry. I. INTRODUCTION An expansion joint is simply a bellows element with end connections. Regardless of accessories, such as liners and covers, it will deflect in any direction or plane that the bellows will. It is the least expensive type, but requires that the piping be controlled as to the direction of the movements required of the unit. The expansion joint should not be expected to control the movement of the pipe. If the piping analysis shows that the expansion joint must accept axial compression, then the piping must be guided and constrained so that only that movement will occur. This expansion joint will not resist any deflections with any force other than the resistance of the bellows, which is a function of the spring rate times the deflection amount. It is incapable of resisting the pressure thrust along its axis, which is the product of the pressure times the effective, or cross sectional, area of the bellows. Large diameter units, even with low pressures, can generate very large axial pressure thrust forces, which must be reacted by main and directional anchors. Otherwise the expansion joint will extend with disastrous results. The bellows is the flexible element of the expansion joint. It must be strong enough circumferentially to withstand the pressure and flexible enough longitudinally to accept the deflections for which it was

Transcript of DESIGN AND ANALYSIS OF EXPANSION JOINTS AND BELLOWS€¦ · DESIGN AND ANALYSIS OF EXPANSION JOINTS...

Page 1: DESIGN AND ANALYSIS OF EXPANSION JOINTS AND BELLOWS€¦ · DESIGN AND ANALYSIS OF EXPANSION JOINTS AND BELLOWS S.VARUNRAJ1, SUDHARSAN.K2 1assistant Professor, Mechanical Department,

DOI:10.23883/IJRTER.2018.4149.QLJI6 430

DESIGN AND ANALYSIS OF EXPANSION JOINTS AND BELLOWS

S.VARUNRAJ1, SUDHARSAN.K2 1assistant Professor, Mechanical Department, Vels Institute Of Science, Technology And Advanced Studies,

Pallavaram, Chennai-117 2assistant Professor, Mechanical Department, Velammal Engineering College, Velammal Nagar, Ambattur-Red

Hills Road, Chennai - 600 066.

Abstract: An Expansion Joints is an assembly designed to absorb the expansion and contraction of

various construction materials, to absorb vibration, or to allow movement due to ground settlement or

earthquakes. An Expansion joint refers to a metal bellows expansion joint designed to absorb axial,

lateral and angular motions in piping system. The bellows is the flexible element of the expansion joint.

It must be strong enough circumferentially to withstand the pressure and flexible enough longitudinally

to accept the deflections for which it was designed, and as repetitively as necessary with a minimum

resistance. This strength with flexibility is a unique design problem that is not often found in other

components in industrial equipment. Since the bellows must accept deflections repetitively, and

deflections result in stresses, these stresses must be kept as low as possible so that the repeated

deflections will not result in premature fatigue failures. In this project a metal expansion joint along with

the bellows and the entire pipe cross over and the pressure parts in the cross over is designed by

considering above words while designing. In the cross over “In line Pressure Balanced Expansion Joint”

is replaced instead of Single Expansion Joints and Elbow Pressure Balanced Expansion Joints is also

present in the cross over. Pressure is applied in the cross over. Design calculation is done manually.

Then the design is modeled in the software Inventor. Then the model is imported by converting it in to

STEP file format to the software Hyper Works. Finite Element Analysis is continued in the software

Hyper Mesh and the results are compared with the manual results. Based on the results, suggestions are

given to the industry.

I. INTRODUCTION

An expansion joint is simply a bellows element with end connections. Regardless of accessories, such as

liners and covers, it will deflect in any direction or plane that the bellows will. It is the least expensive

type, but requires that the piping be controlled as to the direction of the movements required of the

unit. The expansion joint should not be expected to control the movement of the pipe. If the piping

analysis shows that the expansion joint must accept axial compression, then the piping must be guided

and constrained so that only that movement will occur. This expansion joint will not resist any

deflections with any force other than the resistance of the bellows, which is a function of the spring rate

times the deflection amount. It is incapable of resisting the pressure thrust along its axis, which is the

product of the pressure times the effective, or cross sectional, area of the bellows. Large diameter units,

even with low pressures, can generate very large axial pressure thrust forces, which must be reacted by

main and directional anchors. Otherwise the expansion joint will extend with disastrous results.

The bellows is the flexible element of the expansion joint. It must be strong enough circumferentially to

withstand the pressure and flexible enough longitudinally to accept the deflections for which it was

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 431

designed, and as repetitively as necessary with a minimum resistance. This strength with flexibility is a

unique design problem that is not often found in other components in industrial equipment.

Most engineered structures are designed to inhibit deflection when acted upon by outside forces. Since

the bellows must accept deflections repetitively, and deflections result in stresses, these stresses must be

kept as low as possible so that the repeated deflections will not result in premature fatigue failures.

Reducing bending stress resulting from a given deflection is easily achieved by simply reducing the

thickness of the bending member, which in the case of the bellows, is the convolution. However, in

order to withstand the pressure, the convolution, which is also a pressure vessel, must have a thickness

great enough that the pressure induced membrane stresses are equal to or less than the allowable stress

levels of the materials at the design temperatures. This conflicting need for thickness for pressure and

thinness for flexibility is the unique design problem faced by the expansion joint designer.

Most bellows fail by circumferential cracking resulting from cyclic bending stresses, or fatigue. Since

the best design is a compromise, or balance, between pressure strength and flexibility considerations, it

can be concluded that their designs have had lower margins of safety regarding fatigue than they had

regarding pressure strength. The years of experience of the engineers who developed these bellows

assures that the designs contained in this catalog and those offered to satisfy customer specifications,

will have the performance reliability which yields trouble free, safe use. Occasionally, a bellows will

appear to develop a fatigue crack prematurely, i.e., after being subjected to fewer cycles than analysis

indicates they should.

These premature failures usually are the result of one or more of the following causes:

Insufficient margin of safety in the design permitting acceptance of a unit manufactured within a portion

of the dimensional tolerance range to yield a part which will not satisfy the design. Metallic bellows

bending stresses are extremely sensitive to changes in some dimensions, such as the thickness and the

height of the convolution. These dimensional characteristics often affect the various bending stresses by

the square or cube of their differences. An understanding of these dimensional factors and how they can

be controlled during design and manufacture is the key to preventing this cause of early failure. A poorly

manufactured bellows or one that is made to the "wrong" side of the dimensional tolerances will

disappoint the best design and analysis.

Gh. Faraji et al, stated that “Metal bellows have wide applications in aerospace, micro-

electromechanical and industrial systems. Forming process of the metal bellows is v ery sensitive

to increasing the ratio of crown to root diameter. In this state, precise control of the parameters is very

important in order to form high-quality metal bellows with good thickness distribution and desirable

dimensions and resilience. In this paper, a new method has been proposed for manufacturing of the

metal bellows and important parameters such as initial length of tube, internal pressure, axial feeding

and velocity, mechanical properties and the type of materials were investigated by finite element (FE)

analysis (LS-Dyna) and experimental tests. The explicit time integration method is used for modeling

the tube-bulging and folding processes. Meanwhile, the implicit time integration method is used for the

spring back stage. Finally, the results of finite element method (FEM) and experiments show a very

good agreement. The results of the present work could be used as a basis of designing a new type of the

metal bellows.”

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@IJRTER-2018, All Rights Reserved 432

James F. Wilson stated that “A bellows, or a closed thin-walled elastic tube with corrugated walls,

undergoes longitudinal extension when subjected to internal fluid pressure. Investigated herein is the

mechanical behavior of several pressurized bellows in clusters, which are designed to bend and twist as

well as to extend and compress longitudinally. Bellows in clusters can be employed as robotic limbs,

such as manipulator arms and legs for walking machines. For limb bending, analysis shows that there is

an optimal geometry for satellite bellows, or a set of identical bellows clustered longitudinally about a

central core. For limb torsion, the bellows are clustered in a cylindrical helix whose angle is chosen to

produce the desired load–displacement relationships, for instance the highest rotation for a given torque.

For both bending and torsional limbs, experimental results are included that exhibit the predicted

mechanical behavior.”

Moon Yong Lee stated that “The Tubular bellows are one of the most efficient energy-absorbing

elements for various automotive systems. The conventional manufacturing of metallic tubular bellows

consists of a four-step process: (1) deep drawing, (2) ironing, (3) tube bulging, and (4) folding. In the

present study, a single-step tube hydro forming process is used to make prototype tubular bellows with

simultaneous control of the internal pressure and the axial feed. A number of prototype tubular bellows

were formed with the use of various hydro forming die shapes, such as rectangular, circular, and

triangular. For each shape, the hydro formability of the tubular bellows, in conjunction with the forming

process, was evaluated. The effect of the friction was also investigated. Good lubrication is an effective

method for improving the hydro formability of metallic tubular bellows. The present study shows that a

single-step hydro forming process can be used to form tubular bellows with various shapes”.

G. Wang et al stated that “A new forming technology was developed for bellows expansion joints. This

technology uses super plastic forming (SPF) method of applying gas pressure and compressive axial

load. It is developed and can be used to manufacture large diameter “U” type bellows expansion joints

made of titanium alloys. The forming technology for bellows expansion joints made of titanium alloys is

presented to make a two-convolution bellows expansion joint of Ti–6Al–4V alloy as an example.

Welded pipe bent by a hot bending method with a set of specific dies and welded by plasma arc welding

was used as a tubular blank in the SPF. During the SPF process the tubular blank is restrained in a multi-

layer die block assembly which determines the final shape of convolution. The forming load route is

divided into three steps in order to obtain optimum thickness distribution. This technology can also be

used to fabricate stainless steel bellows expansion joints.”

Y.Z.Zhu et al stated that “As experimental research, the effect of environmental medium on corrosion

fatigue life has been proposed in this paper. The research proves the fact that the presence of corrosive

medium will accelerate both crack initiation and propagation rates and reduce the failure life for the

expansion joints. Furthermore, an important suggestion should be made that the effect of environmental

medium on fatigue life must be paid more attention to when dealing with fatigue analysis for bellows

expansion joints.”

Kaishu Guan et al stated “The failure of a bellow expansion joint of 304 stainless steel has been

analysed. Stress corrosion cracking (SCC) caused by wet hydrogen sulfide was responsible for the

failure. Observation of metallographic sections indicated that the crack is transgranular SCC (TGSCC)

with cracking in a direction perpendicular to axial stress. Scanning electron microscopy (SEM) analysis

of the fracture surface showed that the cracks are cleavage and quasi-cleavage with obvious fan-shaped

marking and branched propagation, which indicated that the cracking mode is hydrogen-induced

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 433

cracking (HIC). Metallographic and SEM analysis showed strain-induced marten site transformed from

austenite during the cold working process. This resulted in a considerable susceptibility to sulfide stress

corrosion cracking (SSCC). The quantitative analysis results of XRD indicated that the content of

marten site was up to 44%. The location of HIC at the expansion joint located at crests with maximum

cold work deformation and hardness.”

M. Radhakrishna et al stated that “Previous work by Li et al. in the area of axial vibrations of bellows

dealt with fixd end conditions. However, it is seen on several occasions that bellow ends are welded to a

small pipe spool that has a lumped mass such as a valve or an instrument. Hence, the present paper aims

at finding out the effect of elastically restrained ends on the axial natural frequencies. The analysis

considers finite stiffness axial restraints on the bellows, i.e. solving the set of equations with non-

homogeneous boundary conditions. Two bellow specimens are considered for comparison having the

same dimensions as taken by Li in his analysis. The transcendental frequency equation deduced is

accurate as the first, second and third mode frequencies computed are in close agreement to the ones

obtained by Li.”

S.W.Lee , et al Stated that “The manufacturing process of the metal bellows consists of the four main

forming processes: deep drawing, ironing, tube-bulging and folding. The tube-bulging and folding

processes are critically important because the quality of the metal bellows is greatly influenced by the

forming conditions of these processes. Also, the final convolution shape of the bellows is determined

just after the spring back stage. There are many forming factors pertinent to the overall process of the

metal bellows. The representatives are the wall thickness of the pre-form tube, the pressure applied

during the tube-bulging and the die stroke for the folding stage. In this paper, a finite element analysis

technique is applied to the tube-bulging and folding processes as well as the spring back stage. The

explicit time integration method is used for analyzing the tube-bulging and folding processes.

Meanwhile, the implicit time integration method is used for the spring back stage. Combination of these

two different time integration methods is widely accepted for simulating the forming and spring back

stages consecutively. In addition to the FE simulation, effects of the representative forming factors

mentioned above are examined by using the Taguchi method. From the factor study, the most important

factor influencing the final shape of convolution of the metal bellows is found out. The results of the

present study could be used as a basis of designing a new type of the metal bellows.”

Lu Zhiming et al stated that “The in-plane instability of U-shaped bellows is analyzed. The in-plane

instability critical pressures of bellows which are subjected to zero, tensile and compressive deformation

are measured experimentally. The in-plane instability critical pressure of bellows under compressive

deformation is apparently lower than that under zero deformation, and the in-plane instability critical

pressure of bellows under tensile deformation is higher than that under zero deformation.”

C. BechtIV, et al stated that “Consideration of fatigue is generally an important aspect of the design of

metallic bellows expansion joints. These components are subject to displacement loading which

frequently results in cyclic strains well beyond the proportional limit for the material. At these high-

strain levels, plastic strain concentration occurs. Current design practice relies on use of empirical

fatigue curves based on bellows testing. Prediction of fatigue behavior based on the combination of

analysis and polished bar fatigue data is not considered to be reliable. One of the reasons for the

unreliability is plastic strain concentration. It is shown that the difference between bellows and polished

bar fatigue behavior, as well as the difference between reinforced and unreinforced bellows, can be

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 434

largely attributed to this strain concentration. Further, it is shown that fatigue life of bellows can be

better predicted by partitioning the bellows fatigue data based on a geometry parameter. Determining

dynamic characteristics of bellows by manipulated beam finite elements of commercial software.”

G.I.Broman et al , stated that “A procedure for determining dynamic characteristics of bellows by

manipulating certain parameters of the beam finite elements of I-DEAS Master Series 6 is presented.

The method will work in any software in which these parameters can be set by the user. Compared to a

shell elements model the model size is reduced by at least a factor of 100. This is especially design

parameters. Stress in the bellows cannot be predicted by this method, but when the dynamic behaviour is

known it can be used as input for stress calculations, if desired. In contrast to existing “semi-analytical”

methods this method has the potential of considering axial, bending and torsion degrees of freedom

simultaneously, and it facilitates the interaction between the bellows and the rest of the system, also

modelled by beam or shell finite elements. The procedure is verified by experimental results from other

investigators.”

V. JAKUBAUSKAS et al stated that “This paper considers the transverse vibrations of fluid-filled

double-bellows expansion joints. The bellows are modelled as a Timoshenko beam, and the fluid added

mass includes rotary inertia and bellows convolution distortion effects. The natural frequencies are given

in terms of a Rayleigh quotient, and both lateral and rocking modes of the pipe connecting the bellows

units are considered. The theoretical predictions for the first six modes are compared with experiments

in still air and water and the agreement is found to be very good. The flow-induced vibrations of the

double bellows are then studied with the bellows downstream of a straight section of pipe and a 90°

elbow. Strouhal numbers are computed for each of the flow-excited mode resonances. The bellows

natural frequencies are not affected by the flowing fluid but the presence of an immediate upstream

elbow substantially reduces the flow velocity required to excite resonance.

Tianxiang Li investigates the stresses of Ω-shaped bellows with ideal and elliptic toroids imposed by

internal pressure or deflection, and analyzes the stress distribution state. The calculated stress results of

Ω-shaped bellows with elliptic toroid correspond with our experiment. This paper also analyzes the

effect of the toroid elliptic degree on the bellows stresses. It shows that the toroid elliptic degree needs

to be greatly reduced in the manufacturing process. On the pressure buckling of rectangular bellows for

fusion reactors

Isoharu Nishiguchi and Shinya stated that “Bellows are planned for use in the torus vacuum vessel of

ITER to absorb the relative displacements resulting from thermal expansion. Though both sides of the

bellows are in vacuum during normal conditions, these bellows would be subjected to external or

internal pressures of several MPa during accidents. Since the vacuum vessel forms the tritium boundary

during postulated accidents, the prevention of bellow failure in these events is very important in the

ITER design. For equipping the internal components, rectangular bellows are preferable to circular

bellows in the ITER design. However, investigations concerning pressure buckling of rectangular

bellows are few. Therefore, we investigated the buckling behavior of rectangular bellows and proposed a

simplified evaluation method based on the half pitch model for bellows with a relatively high length-to-

diameter ratio, where elastic column squirm is dominant. For bellows with a lower number of

convolutions, however, inplane squirm buckling should be considered, therefore, we have investigated

inplane squirm of rectangular bellows and compared it with that of circular bellows in this paper.”

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 435

V. F. JAKUBAUSKAS and D. S. WEAVER, Department of Mechanical Engineering, McMaster

University, Hamilton, Ont., Canada, L8S 4L7, stated that “This paper presents the results of an analysis

of the fluid-added mass in bellows expansion joints during bending vibrations. The added mass is shown

to consist of two parts, one due to transverse rigid-body motion and the other due to distortion of the

convolutions during bending. The latter component, neglected in previous analyses, is shown to be

important for relatively short bellows, as are commonly used for expansion joints, and to become

increasingly important for higher vibration modes. The distortion component has been determined using

finite element analysis, and the results are presented in a graphical form for a typical range of bellows

geometries. The total added mass is given in a form suitable for hand calculations.”

II. SOFTWARE USED:

Autodesk® Inventor® 3D mechanical design software provides a comprehensive set of 3D mechanical

CAD tools for producing, validating, and documenting complete digital prototypes. The Inventor model

is a 3D digital prototype that helps users visualize, simulate, and analyze how a design will work under

real-world conditions before a product or part is ever built—helping manufacturers get to market faster

with fewer physical prototypes and more innovative products.

Experience the benefits of Digital Prototyping at your own pace with the most trusted resource for

leveraging and safeguarding your DWG™ data. Inventor software is not only the leader in bringing

innovative capabilities to the manufacturing market, but is also the best-selling 3D mechanical design

software, having outsold all competitors seven years running.

Features & Specifications

The Autodesk® Inventor® software line provides a comprehensive set of tools for producing,

validating, and documenting complete 3D digital prototypes. Learn how Autodesk Inventor software

helps designers create accurate 3D digital prototypes and bring better products to market faster and at

less cost.

Hyper Mesh:

Hyper Mesh is a high performance finite element method pre-processor for popular finite element

solvers that allows engineer to analyze product design performance in a highly interactive and visual

environment. Hyper Works is a user interface is easy to learn and supports number CAD geometry and

finite element model file formats, thereby increasing interoperability and efficiency.

Advanced functionally within the Hyper mesh allows users to efficiently manipulate geometry and

highly complex models. These functionalities include extensive meshing and model control, morphing

technology to update existing meshes to new design proposals and automatic mid-surface generation for

complex designs with varying wall thickness.

Solid geometry enhances tetra-meshing and hexa-meshing by reducing interactive modeling times, while

batch meshing enables large-scale meshing parts with no manual clean-up and minimal user input.

III. BENEFITS

1. Open-Architecture Design With the broadest set of direct CAD and CAE interfaces coupled with the users-defined integrations,

Hyper Works fits seamlessly with any simulation environment.

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 436

2. High-Speed, High-Quality Meshing

With both automatic and semi-automatic shell, tetra-and hexa-meshing capabilities, Hyper Works

simplifies the modeling, process of complex geometries.

3. Closes the loop between CAD and FEA

Create surfaces from the finite elements enabling analysis engineers to communicate results and design

modifications back into the design environment.

4. Reduces Model Assembly Time

Leverage highly automated methods for rapid model assembly that create connections such as

bolts, spot welds, adhesives and seam welds.

IV. OUTPUT OBTAINED :

MODELLING OF EXPNSION JOINTS ALONG WITH THE CROSS OVER USING

INVENTOR

Figure 1 Metal Expansion Joints Along with Cross Over

Figure 2 Elbow Pressure Balanced Expansion Joints

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 437

Figure 3 Elbow Pressure Balanced Expansion Joints

Figure 4 In Line Pressure Balanced Expansion Joint

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 438

Figure 5 Side View

Figure 6 Mitter

Modeling is done by using the software INVENTOR. Modeling was completed using the student

licensed version of Autodesk Inventor Professional 2009.

V. ANALYSIS OF EXPANSION JOINTS

MESHING:

In this project analysis part is continued in two software’s. One is Hyper Mesh which is used

only for the MESHING purpose. Finally solving was proceeded in ANSYS.

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@IJRTER-2018, All Rights Reserved 439

DATAS OF LP TURBINE A:

Table 1 DATAS OF LP TURBINE A

COMPONENTS PIPE TIE ROD SUPPORT RING BELLOW

MATERIAL USED A 516 Gr. 74 A 193 Gr. 2H A 516 Gr. 70 A 240 TYP 316

YIELD STRENGTH 264 MPA

YOUNGS MODULUS 25058000 PSI 25996000 PSI 25058000 PSI 24562000 PSI

THICKNESS 25 94 95

TOAL LOAD 298091.278 kgs

DATAS OF LP TURBINE B:

Table 2 DATAS OF LP TURBINE B

COMPONENTS PIPE TIE ROD

SUPPORT

RING BELLOWS

MATERIAL USED A 516 Gr. 74 A 193 Gr. 2H A 516 Gr. 70

A 240 TYP

316

YIELD STRENGTH 264 MPA

YOUNGS MODULUS 25058000 PSI 25996000 PSI 25058000 PSI 24562000 PSI

THICKNESS 16 72 80

TOAL LOAD 173320.55 kg

7.2 LOAD CONSTRAINTS:

Young’s Modulus E FOR PIPE = 25058000 PSI, CARBON STEEL – A 105, A516, A515

Young’s Modulus E FOR ROD = 25996000 PSI

Young’s Modulus E FOR BELLOW = 24562000 PSI

TENSILE MUST ACTS ON THE TIE ROD,

BENDING LOADS ON SUPPORT RING, NO GROOVES ON SUPPORT RING,

Total load acts on the 95 mm (LP Turbine A) thickness Support Ring = 298091.278 kg

Total load acts on the 80 mm(LP Turbine B) thickness

Support Ring = 173320.55 kg

Height of the bellow A = OD=1610 mm, ID= 1490 mm

Height of the bellow B = OD= 1217 mm, ID = 1097 mm

Thickness of bellow is 2 mm

Number of convolution is 6

Total Pressure applied in the entire model is 15 bars and it is maintained throughout the system.

Total pressure thrust load created by Bellow acts on the support ring that on support ring of LP TURBINE A and B

So, bending moment on the support thing and because of this load there is a formation of tensile

stress on the tie rods.

Pressure thrust load acts on the gusset or Shear Lug which is welded with the support ring.

Tie rod is connected with the support ring and because of load transfers to tie rod.

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

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7. 3. MESHING IN HYPER MESH

Figure 7 Meshing Done In Expansion Joint Using Hyper Mesh

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@IJRTER-2018, All Rights Reserved 441

7.4. ANALYSIS IN ANSYS

7.4.1. LOAD CONSTRAINTS

Figure 8 load constraints in LP Turbine A

Figure 9 Constraints in LP Turbine B

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Fig 7.4.1.3 Pressure applied entirely in Cross over

Figure 10 Nodal solution in Y

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Figure 11 Nodal solution in Z

Figure 12 Stress formation

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Figure 13 Stress formation in Mitter

Figure 14 Stress formation Elbow Expansion Joint

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Figure 15 In Line Pressure Balanced Expansion joints

Figure 16 Stress formation in Support ring

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Figure 17 Stress in support ring area

Figure 18 Max Displacement of Tie Rod

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7.4.2. MODIFICATION BY CHANGING THICKNESS IN THE AFFECTING AREA

Figure 19 Nodal solution in X

Figure 20 Nodal solution in Y

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Figure 21 Nodal solution in Z

Figure 22 Stress Formation

Figure 23 Stress Formation

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Figure 24 Max Displacement

Figure 25 Stress Formation in Mitter

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Figure 26 Stress Formation on Elbow area

Figure 27 Stress Formation on In Line area

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Figure 28 Stress Formation on Support Area

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Figure 29 Stress and maximum displacement of Support Ring and Rod

VI. RESULTS

Given design is modeled and analyzed by using Hyper Mesh 9 and

Ansys 10

Max yield strength for the material in PIPE is 264 MPA

For the first result it came as 214 as maximum

Here stress concentrated areas are Elbow Joint, In Line Joint and Mitter

For the Safety factor the thickness of that area it is increased to 25 mm

Once again analyzed and solved it came below 140 MPA.

Allowable Stress is 157 MPA and considering factor safety 10% and allowable stress is (157-15.7 = 142.3 MPA), so allowable stress is above.

Stress diagrams are attached above which came as output in Ansys 10

Support Ring is very much safe in this pressure

Displacement of tie rod is calculated

VII. SUGGESTIONS

Support ring and gusset thickness can be reduced up to 10 mm

Mitter thickness can be reduced to 5 mm

So, it will reduce the self weight of the Cross over

Cost of material can be minimized

Thickness of the stress concentrated areas can be raised up to 2 to 4 mm considering the safety

factor.

REFERENCES I. Failure of 304 stainless bellows expansion jointKaishu Guana, Xinghua Zhangb, Xuedong Guc, Longzhan Caic, Hong

Xua and Zhiwen Wanga. from Science Direct Experimental and Finite Element Analysis of Metal Bellows

Manufacturing

III. G. Faraji, H. Kashanizadeh, M. Mosavi, and M.K. Besharati The effect of environmental medium on fatigue life for u-

shaped bellows expansion joints

IV. Y.Z. Zhu, H.F. Wang and Z.F. Sang. From Science Direct. Active Damper using Fuzzy Controller, Rafael Luís

Teixeira Federal University of Uberlândia College of Mechanical Engineering Campus Santa Mônica - Uberlândia-

MG- Brazil. From IEEE

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 453

V. METAL EXPANSION JOINT INSTALLATION AND HANDLING INSTRUCTIONS, by Expansion Joint Systems,

Inc

VI. Bellows Design for the PEP-II High Energy Arc Chambers, M.E.Nordby, N.Kuirta

VII. g. Strain and Fatigue Testing Of Large Expansion Bellows, by D.K.Sharma, R. Henschel and M.Krawchuk

VIII. Expansion joint covers,Expansion joint covers, portal plus 639, Thomas drive, Bensenville, IL60106

IX. Expansion Joint covers, published by felt tips, Contributed by Scott Sider, ccs ,april 1995

X. INFLUENCE OF MICRO-DAMAGE ON RELIABILITY OF CRYOGENIC BELLOWS IN THE LHC

INTERCONNCTIONS, C. Garion1, B. Skoczen*

XI. Expansion joint designs for inquiries and fabrication. Compensator design reviews. KOG Fabricators, 2006

XII. Design of various high temperature expansion joints and special items, 3D modeling and manufacturing drawings, J

Tolonen Services cc, KOG Fabricators

XIII. Complex expansion joint designs for inquiries and fabrication. Arminco, 2002

XIV. Expansion joints bellows and stress analysis, by engineering applicances.