Study on stress concentration and fatigue life of tubing with slip indentation

Abstract

The indentation caused by slip on the outer wall of tubing is a significant contributor to stress concentration and, consequently, fatigue failure in the tubing string. Through an analysis of the interaction between slips and tubing, a mathematical model to predict slip-tubing interaction and slip crushing load is formulated, accounting for external pressure, internal pressure, and axial forces. On this basis, the influence factors and influence rules of slip crushing load are studied, and three-dimensional yield surface and tri-axial stress ellipse of tubing are investigated, considering different transverse load factors and design factors. To accurately forecast the fatigue life of tubing subjected to slip indentation, two models are established: one for fatigue life prediction and the other for tubing string vibration. In order to quantitatively assess the stress concentration arising from slip indentation, a finite element model of tubing featuring slip indentation is established. Finite element analysis reveals that stress concentration and non-uniformity are evident in the vicinity of slip indentation, with their severity intensifying as the indentation depth grows. The initial step in assessing fatigue life involves fatigue life tests on tubing material subjected to varying stress levels. Subsequently, a case study is conducted and the variations of wellhead pressure and axial stress are evaluated. Fatigue life analysis reveals that the fatigue life is notably sensitive to variations in stress amplitude and slip indentation depth. An increase in the magnitude of alternating stress and the depth of slip indentation will result in a significant reduction in the fatigue lifespan. The methodologies employed in this research, along with the resulting findings, offer a robust theoretical framework and a solid practical basis for forecasting and managing stress concentration and fatigue durability in tubing affected by slip indentation.