Thermally-Assisted Rotational Autofrettage of Long Cylinders with Free Ends

Abstract

Autofrettage is a widely employed process for strengthening cylindrical or spherical pressure vessels. The process involves applying a uniform load to the inner wall of a vessel to cause a controlled plastic deformation, where the vessel yields starting from the inner wall up to an intermediate radius. When the load is removed, elastic recovery takes place and compressive residual stresses are induced in the vicinity of the inner wall, which strengthen the vessel against high static and pulsating loads during service. Based on the load employed, autofrettage can be of five types- hydraulic, swage, explosive, thermal and rotational. This work analyzes a rotational autofrettage augmented by a thermal load where the load is applied by rotating the cylinder about its axis while maintaining a temperature gradient across the wall. The combined centrifugal and thermally-induced stresses cause plastic deformation in the cylinder. When the cylinder is unloaded by bringing it to rest and cooling down to room temperature, compressive hoop residual stresses are introduced in the vicinity of the inner wall. A finite element method model of the proposed thermally-assisted rotational autofrettage is developed for a cylinder made of AH36 mild steel in a commercial package ABAQUS®. The results indicate that the thermal load reduces the rotational speed required for autofrettage, when compared to a conventional pure rotational autofrettage. The thermal load also mitigates the tensile axial residual stresses, which are typical in a purely rotational autofrettage. A conceptual design of the experimental set up is also presented.