Universal Journal of Engineering Science 5(3): 44-55, 2017 http://www.hrpub.

org
DOI: 10.13189/ujes.2017.050302

Optimum Autofrettage Pressure for a High Pressure

Cylinder of a Waterjet Intensifier Pump
Hakan Çandar*, İ. Hüseyin Filiz

Department of Mechanical Engineering, University of Gaziantep, Turkey

*Corresponding Author: [email protected]

Copyright©2017 by authors, all rights reserved. Authors agree that this article remains permanently open access under the
terms of the Creative Commons Attribution License 4.0 International License

Abstract This study presents analytical approach for compressive stress at the inner surface is achieved.
the determination of optimum autofrettage pressure of a Analytical model for autofrettage process first proposed
thick walled cylinder which is commercially used as a high by Hill [1] is elastic-perfectly plastic model. Many
pressure cylinder of a waterjet intensifier pump. Bilinear researchers have been used this model in their studies.
kinematic hardening model is used in the derivation of Topçu and Filiz [2] compared the performance
analytical model based on plane strain, Von-Mises yield characteristics of shrink fit and autofrettage process by
criteria and incompressible volume assumptions. going through analytical and numerical analysis. Majzoobi
Elasto-plastic radius is dependent on autofrettage pressure et al. [3] studied on the determination of the best
and optimum value of autofrettage pressure is found as a autofrettage pressure by going through analytical and
value that will give minimum value of maximum numerical analysis. Hojjati and Hassani [4] stated the
Von-Mises stress on the wall of the cylinder under optimum autofrettage pressure and radius by theoretically
operating pressure. Hence, considering elasto-plastic radius and by finite-element modeling based on von misses
as the design variable, its optimum value is determined for yielding criteria. Rayhan et al. [5] pointed out that working
the specified operating pressure. Reverse yielding owing to pressure and the ratio of outer to inner radius effects the
Bauschinger effect is used as the only non-linear constraint, optimum autofrettage pressure.
Matlab© optimtool finds optimum value of the Elastic-perfectly plastic assumption cannot be used for
elasto-plastic radius and the corresponding autofrettage most of the materials due to Bauschinger effect and strain
pressure is then calculated. By using ANSYS 15©, stress hardening. Huang [6] proposed an autofrettage model
analysis of the autofrettaged cylinder has been performed considering the material strain hardening relationship and
and the results obtained from both methods are found to be Bauschinger effect, based on actual tensile-compressive
almost the same. curve of material. He found that the smaller Bauschinger
effect coefficient causes the reverse yielding to take place
Keywords Autofrettage, Kinematic Hardening, more easily and affects the residual stress distribution.
Bauschinger Effect, Optimization, FE Analysis White et al. [7] developed an improved isotropic-kinematic
hardening model and they defined the Bauschinger effect as
one of the most important physical properties to be
modelled. EunYeup Lee et al. [8] investigated elastic-
1. Introduction perfectly plastic and strain hardening models for
autofrettaged compound cylinder. They found that the
High pressure cylinders of a waterjet intensifier pump are compressive residual stress of the strain hardening model is
subjected to an alternating internal pressure at a certain smaller than that of the elastic- perfectly plastic model
frequency. Failure of these cylinders is due to higher values because of the Bauschinger effect. Ragab et al. [9] used a
of alternating stress components at the inner surface. In order generalized material behaviour model includes reverse
to improve fatigue behaviour of these cylinders a yielding, non-linear hardening and Bauschinger effect.
compressive residual stress at the inner surface must be In this study, going through the studies mentioned above,
created. Autofrettage process is one of the efficient methods an analytical model is generated in order to evaluate the
using for this purpose. In the autofrettage process, a certain value of the optimum value of elasto-plastic radius so that
amount of internal pressure is applied to the cylinder so that maximum Von-Mises stress developed on the wall of the
the inner part of its wall becomes partially plastic. The cylinder will be minimized under operating pressure.
pressure is then released and the outer elastic part of the wall Autofrettage pressure, elasto-plastic radius and operating
tries to compress the inner plastic part. Thus, residual pressure are all interrelated to each other. Loading the
 Universal Journal of Engineering Science 5(3): 44-55, 2017 45

cylinder with autofrettage pressure and then unloading the And, the elastic constitutive relations are;
cylinder will create compressive residual stress at the inner
Eεr = σr − υ(σθ + σz )
surface of the cylinder which will help in reducing the
stresses developed under operating pressure. The problem Eεθ = σθ − υ(σr + σz )
here is to determine the optimum value of autofrettage
pressure which gives minimum Von-Mises stress under Eεz = σz − υ(σr + σθ ) (3)
operating pressure. Due to kinematic hardening behaviour, During autofrettage process, the cylinder is located
autofrettage pressure is limited to a value at which reverse between two holders that restrict the elongation in
yielding begins. This is considered as a nonlinear constraint longitudinal direction which results plain strain case.
in optimization process. By using Matlaboptimtool, Another consideration is about material stress-strain
optimum value of elasto-plastic radius is determined. relationship. It is assumed that equivalent stress-strain
Optimum autofrettage pressure and corresponding relationship is the same as stress-strain relationship of
Von-Misses stresses through the wall of the cylinder are simple tension-compression test. In addition to these,
then calculated. In order to verify the results, finite element incompressible volume assumption (εr+εθ+εz=0) and Von
model of the cylinder is created in ANSYS environment and Misses yielding criteria are used. Von-Mises criterion
the results obtained from both analytical and FEM analyses suggests that, equivalent stress (Von Misses stress) σi, and
are compared. equivalent strain εi are:

1
σi = � [(σθ − σr )2 + (σr − σz )2 + (σz − σθ )2 ] (4)
2
2. Theoretical Analysis
√2
εi =
3
�[(εθ − εr )2 + (εr − εz )2 + (εz − εθ )2 ] (5)
2.1. Basic Equations
For plain strain assumption, εz=0, equation (3) gives;
When a hollow cylinder with closed ends is pressurized 1
as shown in Figure 1, radial stress (σr), tangential stress σz = (σθ + σr ) (6)
2
(hoop stress, σt) and longitudinal stress (σz) are developed.
Substituting equation (6) into equation (4) gives;
These stresses are the principal stresses. From the force
equilibrium on the infinitesimally small element, equation 1
σz = (σθ + σr ) (7)
(1) is obtained. 2
1
σr + r
𝑑𝜎𝑟
− σθ = 0 (1) σz = (σθ + σr ) (8)
𝑑𝑟 2

And, corresponding strains εr and εθ are given in terms of The radial stress σr can be obtained from equations (1)
the radial displacement, u, as: and (7);
du 1
σz = (σθ + σr ) (9)
εr = 2
dr
εθ =
u
(2) And equivalent strain is obtained from equations (2) and
r (5) and by using plane strain and incompressible volume
assumptions;
1
σz = (σθ + σr ) (10)
2

Where, c is integration constant.

2.2. Stress-Strain Relationship

In general, materials exhibit different characteristics in
elastic and plastic region. In this work, material stress-strain
relationship is assumed to be bilinear kinematic hardening
model which is shown in Figure 2. The model is considered
to consists of elastic region (O-A) and plastic region (A-B)
Figure 1. Cross section of a thick walled cylinder under internal pressure
and can be described by two equations.
46 Optimum Autofrettage Pressure for a High Pressure Cylinder of a Waterjet Intensifier Pump

Substituting equations (10), (11) and (15) into equation (8)

gives;

σze = ce2 (17)

b) Plastic region (A-B)
Substituting equations (10) and (13) into equation (9)
gives;
2 2 T
σrp = A ln r − c + cp2 (18)
√3 3 r2 p1

Substituting equations (10) and (13) into equation (7)

gives;
2 2 T
σθp = A(1 + ln r) + c + cp2 (19)
√3 3 r2 p1

Substituting equations (10) and (13) into equation (8)

gives;
2 2 T
σθp = A(1 + ln r) + c + cp2 (20)
√3 3 r2 p1
Figure 2. Material stress strain curve based on bilinear kinematic
hardening model Boundary conditions
The following boundary conditions exist when the
Elastic region (O-A)
cylinder is subjected to internal pressure Pa as shown in
1
σz = (σθ + σr ) (11) Figure 3.
2

Plastic region (A-B)

σ = Sy + T. �εp − εy � (12)
Where, Sy, εy, εp and T are yield stress, yield strain, plastic
strain and tangent modulus respectively. Arranging equation
(12) yields,
σ = Sy + T. �εp − εy � (13)
Where, A is a constant and depends on Sy, εy and T.
A = Sy − T. εy 14)

2.3. Stress Analysis

Stresses developed in the loading and unloading stages of
autofrettage process are analyzed by using proper boundary
conditions. Stresses in the operating stage are considered to
be superposition of residual stresses and the elastic stresses Figure 3. Radii of elastic-plastic zones
due to the operating pressure.
1. Both of the equivalent stresses in the elastic zone and
2.3.1. Loading Stage plastic zone (r=b) are equal the yield stress of the
material.
a) Elastic region (O-A)
a) at r=b, σie=Sy, ce1 is found as;
Substituting equations (10) and (11) into equation (9) √3 Sy
gives; ce1 = b2 (21)
2 E

σre = −
2 E
c + ce2 (15) b) at r=b, σip=Sy, cp1 is found as;
3 r2 e1
√3 �Sy −A�
Substituting equations (10), (11) and (15) into equation (7) cp1 = b2 (22)
2 T
gives;
2. The radial stress σr at the outer surface (r=c) and the
2 E inner surface (r=a) are equal to zero and –Pa
σθe = c + cθ2 (16) (autofrettage pressure) respectively.
3 r2 θ1
a) at r=c, σre=0, ce2 is found as;
 Universal Journal of Engineering Science 5(3): 44-55, 2017 47

1 b2 a2 c2
ce2 = S (23) −Pa − Pa �1 + 2 � (35)
√3 y c2 c2 −a2 r

b) at r=a, σrp=-Pa, cp2 is found as; 1 2 r 1 b2

σzp = A+ A ln + �Sy − A� 2 − Pa
2 1 b2 √3 √3 a √3 a
cp2 = − A ln a + �Sy − A� − Pa (24)
√3 √3 a2 a2
−Pa (36)
c2 −a2
Loading stress distribution
2.3.3. Operating Stage
a) Elastic region (O-A)
When the operating pressure is acting, the stresses
Substituting equations (21) and (23) into equations (15) to developed in the cylinder will be reduced due to compressive
(17) gives; residual stresses developed at the inner surface of the
σre =
1
S b2
1
� 2 − 2�
1
(25) cylinder.
√3 y c r
1 1 1 a) Stresses developed in elastic part of the cylinder
σθe = S b2 � 2 + 2� (26) under operating pressure (b≤r≤c)
√3 y c r
1 b2 1 1 1 a2 c2
σze = S (27) σre = Sy b2 � 2 − 2 � − Pa 2 �1 − �
√3 y c2
√3 c r c − a2 r2
b) Plastic region (A-B) a2 c2
+Pw �1 − 2 � (37)
c2 −a2 r
Substituting equations (22) and (24) into equations (18) to
(20) gives; 1 1 1 c2 a2
σθe = Sy b2 � 2 + 2 � − Pa 2 �1 + 2 �
√3 c r c −a 2 r
1 1 1 a2 c2
σre = S b2 � 2 − 2 � − Pa �1 − 2 � (28) a2 c2
√3 y c r c2 −a2 r +Pw �1 + r2 � (38)
c2 −a2
2 r b2 1 1
σθp = A �1 + ln � + �Sy − A� � + 2 � (29) 1 b2 a2 a2
√3 a √3 a2 r σze = S − Pa + Pw (39)
√3 y c2 c2 −a2 c2 −a2
1 2 r 1 b2
σzp = A+ A ln + �Sy − A� − Pa (30) b) Stresses developed in plastic part of the cylinder
√3 √3 a √3 a2
under operating pressure (a≤r≤b)
2.3.2. Unloading Stage
2 r b2 1 1
When the autofrettage pressure is totally removed, the σrp = A ln + �Sy − A� � 2 − 2 � − Pa
unloading will be elastic if there is no reverse yielding. In √3 a √3 a r
this case, unloading stresses follow the Lame equations. As a a2 c2 a2 c2
−Pa �1 − 2 � + Pw �1 − 2 � (40)
c2 −a2 r c2 −a2 r
result, residual stresses developed elastic and plastic parts of
the cylinder are calculated as; 2 r b2 1 1
σθp = A �1 + ln � + �Sy − A� � 2 + 2 �
√3 a √3 a r
a) Residual stresses developed in elastic part of the 2 2
cylinder (b≤r≤c) a c
−Pa − Pa 2 2
�1 + 2 �
c −a r
1 1 1 a2 c2
σre = S b2 � 2 − 2 � − Pa �1 − 2 � (31) a2 c2
√3 y c r c2 −a2 r
+Pw �1 + r2 � (41)
c2 −a2
1 1 1 a2 c2
σθe = S b 2
� 2 + 2 � − Pa �1 + 2 � (32) 1 2 r 1 b2
√3 y c r c2 −a2 r
σzp = A+ A ln + �Sy − A� 2 − Pa
1 b2 a2 √3 √3 a √3 a
σze = S − Pa (33)
√3 y c2 c2 −a2 𝐚𝟐 𝐚𝟐
−𝐏𝐚 + 𝐏𝐰 (42)
𝐜 𝟐 −𝐚𝟐 𝐜 𝟐 −𝐚𝟐
b) Residual stresses developed in plastic part of the
cylinder (a≤r≤b) 2.4. Autofrettage Pressure
2
2 r b 1 1 The autofrettage pressure can be obtained by equating
σrp = A ln + �Sy − A� � 2 − 2 � − Pa
√3 a √3 a r radial stress components at elastic plastic interface (r=b).
a2 c2 That is:
−Pa �1 − 2 � (34)
c2 −a2 r σre=σrp(at r=b)
2 r b2 1 1 1 b 1 1 1 1
σθp = A �1 + ln � + �Sy − A� � 2 + 2 � Pa = �2A ln + �Sy − A�b2 � − � − Sy b2 � 2 − ��
√3 a √3 a r √3 a a2 b2 c b2
(43)
48 Optimum Autofrettage Pressure for a High Pressure Cylinder of a Waterjet Intensifier Pump

3. Determination of Optimum High pressure cylinders are essential part of the intensifier
pump where ultra-high pressure (410 MPa) develops. In the
Autofrettage Pressure design of these cylinders, alloy steels are widely used due to
some mechanical properties such as high strength to weight
3.1. High Pressure Cylinder of a Waterjet Intensifier ratio, toughness, resistance to fatigue and corrosion. In this
Pump intensifier unit AISI 4340 alloy steel is used as the cylinder
material. The cylinder has 14 mm inner, 38 mm outer radius
Intensifier pump is the heart of a waterjet cutting machine
and 160 mm length. Chemical composition, mechanical
and mainly consists of piston assembly, check valve
properties and tensile stress-strain relationship are given in
assemblies, low pressure cylinder and high pressure
Table 1,2 and Figure 5 respectively.
cylinders as shown in Figure 4.

Figure 4. Sectional view of an intensifier pump [10]

Table 1. Chemical composition of AISI 4340 alloy steel [11]

%Fe %Ni %Cr %C %Mo %Others

96.6 1.8 0.8 0.4 0.25 0.1

Table 2. Mechanical properties of AISI 4340 [11]

Tangent Modulus
Treatment Syt [MPa] Syc [MPa] Sut (MPa) E (GPa) HB ν
(MPa)
Q&T (5100C) oil 1200 1130 1270 200 1489 400 0.3

Figure 5. Tensile stress-strain curve of AISI 4340 [11]

 Universal Journal of Engineering Science 5(3): 44-55, 2017 49

Figure 6. Stress distribution for non-autofrettaged high pressure cylinder under operating pressure of 410 MPa

Figure 7. Von misses stress developed at elasto-plastic radius due to operating pressure for different autofrettage pressures

Without autofrettage process the stresses developed As seen in equation (43), for a specific cylinder,
through the wall of the cylinder is easily calculated by using Autofrettage pressure becomes the function of elasto-plastic
Lame equations. Figure 6 represents all stress components of radius and the problem is a one variable optimization
the cylinder under 410 MPa operating pressure. It is seen in problem with a nonlinear constraint. By using constrained
the figure that maximum von misses stress (821,7MPa) nonlinear minimization solver with interior point algorithm
occurs at the inner surface of the cylinder. It is actually this in MatlabOptimtool the optimum amount of elasto-plastic
stress magnitude which will result fatigue failure for cyclic radius is determined.
loading. This level is reduced by the compressive residual After autofrettage process, von misses stress distribution
stress due to autofrettage process which will result an under operating pressure decreases through the wall of the
increase in fatigue life. cylinder and the maximum von misses stress occurs at the
elasto-plastic radius. Thus, objective function is the
3.2. Optimization minimization of von misses stress at this point and written as;
Minimize, f=σie =σip, at r=b
The amount of autofrettage pressure is to be applied in the When the autofrettage pressure is removed (unloading
wall of the cylinder is an important issue in the autofrettage stage) residual von misses stress must not exceed yield stress
process. With an increase in the autofrettage pressure, in compression of the material which depends on the amount
maximum von misses stress at critical section (elasto-plastic of strain hardening. Otherwise, reverse yielding starts due to
radius) in operating stage decreases to a minimum value, but Bauschinger effect. This is a nonlinear inequality constraint
after a specific value of autofrettage pressure it begins to and expressed as;
increase as shown in Figure 7. σ′ unloading ≤S′yc where S′yc = 2Sy − σ′ loading , at r = a
50 Optimum Autofrettage Pressure for a High Pressure Cylinder of a Waterjet Intensifier Pump

σ′ unloading ≤2Sy − σ′ loading boptimum= 18.862 mm

σ′ loading + σ′ unloading − 2Sy ≤0 and by substituting it in equation (45), optimum autofrettage
Another consideration is the lower and upper limits of pressure is calculated as;
elasto-plastic radius (b), which must be between inner radius
Paoptimum= 936.260 MPa
(a) and outer radius (c);
a<b<c Stress distributions through the wall of the cylinder;
loading, unloading and operating stages are given in Figures
Results 8, 9, 10 respectively. Maximum von misses stress is formed
From all this considerations, optimum elasto-plastic radius at elastic-plastic interface as shown in Figure 10 and it is
is found as; decreased to 618.93 MPa from 821.7 MPa comparing to
non-autofrettaged cylinder.

Figure 8. Stress distributions through the wall of the cylinder-loading stage

 Universal Journal of Engineering Science 5(3): 44-55, 2017 51

Figure 9. Stress distributions through the wall of the cylinder-unloading stage

Figure 10. Stress distributions through the wall of the cylinder-operating stage

4. FEM Analysis the default parameters of ANSYS® are used for the rest.
Analysis is performed in three steps for loading, unloading
2D Finite element model is created in ANSYS® and operating stages. A path is selected from the inner wall to
Workbench 15.0 to validate the analytical model. Quarter of the outer surface to evaluate the stress values with respect to
the cylinder is modeled by using symmetric boundary
radial distance along the thickness. Figures 11 to 13
conditions and plane strain method is selected for the
represent the stress distributions for each stage. It is seen that
analysis. Uniform and regular meshes are used with 0.1mm
the stress values are almost same with the analytical results;
element sizes. Bi-linear kinematic hardening model is used
there are only slight differences in axial stress values.
to describe the stress-strain relationship of the material and
52 Optimum Autofrettage Pressure for a High Pressure Cylinder of a Waterjet Intensifier Pump

Figure 11. FEM results for all the stress components in the loading stage

Figure 12. FEM results for all the stress components in the unloading stage
 Universal Journal of Engineering Science 5(3): 44-55, 2017 53

Figure 13. FEM results for all the stress components in the operating stage

Von-Misses stress distributions along the wall of the cylinder for loading, unloading and operating stages are also
represented in Figures 14 to 16. In the loading stage, the maximum Von Misses stress is developed on the inner wall of the
cylinder is shown in Figure 14, with a value of 1208,8 MPa which is smaller than the ultimate tensile strength of the material
(Sut=1270 MPa). This means that, the pressure value (Pa=936.26 MPa) can be safely used. After the autofrettage pressure is
removed (unloading stage), the maximum Von Misses stress is still developed on the inner wall with a value of 669.31 MPa
which is smaller than the yield strength in compression of the material (Syc=1130 MPa) as shown in Figure 15. When the
operating pressure is applied, the maximum Von Misses stress is developed at the elastic-plastic interface as shown in Figure
16 with a value of 618.04 MPa which is almost the same as the analytical result (618.93 MPa).

Figure 14. Von Misses stress distribution-loading stage

54 Optimum Autofrettage Pressure for a High Pressure Cylinder of a Waterjet Intensifier Pump

Figure 15. Von Misses stress distribution-unloading stage

Figure 16. Von Misses stress distribution-operating stage

 Universal Journal of Engineering Science 5(3): 44-55, 2017 55

Von Misses stresses obtained from analytical and REFERENCES

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