ARTICLE KD-5

DESIGN USING AUTOFRETTAGE

KD-500 SCOPE (b) The effects of these residual compressive tangen-

tial stresses are to:
This Article provides means to calculate residual
(1) increase the value of any subsequent applica-
stress distribution after autofrettage has been performed,
in straight single wall cylinders with no crossholes or tion of internal pressure which will cause the onset of
discontinuities. Numerical elastic–plastic analyses or additional permanent deformation of the cylinder;
experimental techniques may be used for more complex (2) reduce the effective mean stress value of the
geometries. Other approaches may be used if they can cyclic bore stresses and thus increase the fatigue life;
be shown to be conservative. (3) reduce the effective fracture mechanics stress
Autofrettage is one of several processes that can be intensity factor at the tip of a crack or cracklike flaw
used to produce favorable residual stresses in thick- near the bore due to internal pressure. This will retard
walled pressure vessels. Autofrettage may be used alone the growth of fatigue or stress corrosion cracks near
or combined with other processes such as shrink fitting the bore surface.
or wrapping to produce a more favorable residual
stress distribution than can be conveniently produced
by autofrettage alone. See Article KD-8 for rules on
KD-502 Nomenclature
combining these residual stresses.
The method for vessel fatigue design accounting for Acsp cross-sectional area normal to the longitudinal
the residual stresses produced by autofrettage is given axis
in Articles KD-3 and KD-4. The guidelines for accom- Dp diameter of the cylindrical vessel at any point
plishing the autofrettage operation are given in Article in the wall
KF-5. DIp inside diameter
DOp outside diameter
DPp diameter of the plastic–elastic interface before
unloading the autofrettage pressure
KD-501 Theory
DZp diameter where ␴tRA p ␴rRA
(a) The theory of autofrettage is based on the fact Ep elastic modulus
that the stress in a thick-walled cylindrical vessel is Fbp correction factor for the Bauschinger effect for
higher at the bore than at the outside surface for a DZ ≤ D ≤ DP
given internal pressure. If such a vessel is subjected Flp force in the longitudinal direction
to a continuously increasing pressure, the entire vessel PAp maximum pressure applied during the autofret-
will deform elastically until some pressure is reached tage operation
at which the material at the bore begins to plastically Syp actual measured yield strength of the material
deform. As the pressure continues to increase, the being autofrettaged at the temperature at which
boundary at which material begins to yield moves from the autofrettage is performed
the bore through the vessel wall until it reaches the Yp ratio of DO /DI
outer wall, causing plastic collapse [see KD-210(e)(6)]. ⑀mp average value of the maximum tangential strain
In the process of autofrettage, the pressure is increased on the outside surface of the vessel, taken at a
from the point of first yielding at the bore to a pressure minimum of three axial locations and measured
that will place the elastic–plastic interface at the desired at the maximum pressure used for the autofret-
radius. The removal of this pressure then produces tage operation PA
compressive residual tangential stress at the bore and ⑀pp average value of the permanent tangential strain
tensile residual tangential stress at the outer wall. on the inside surface of the vessel, taken at a

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 KD-502 PART KD — DESIGN REQUIREMENTS KD-521.3

minimum of three axial locations and measured therefore need not be considered in design calculations.
after the release of the autofrettage pressure However, when longitudinal stresses must be considered
␴ADp value of ␴tRA at D p DI near discontinuities, the longitudinal residual stress due
␴CDp value of the residual tangential stress at D p to autofrettage shall be neglected.
DI corrected for the Bauschinger effect
␴rRp residual radial stress corrected for the
Bauschinger effect KD-521 Calculation of the Elastic–Plastic
␴rRAp first approximation of the residual radial stress Interface Diameter
after autofrettage for DI ≤ D ≤ DP
The diameter of the elastic–plastic interface DP may
␴tRp residual tangential stress corrected for the
be determined from one or more of the following
Bauschinger effect
measurements:
␴tRAp first approximation of the residual tangential
(a) ⑀m;
stress after autofrettage for DI ≤ D ≤ DP
(b) ⑀p;
␯p Poisson’s ratio
(c) PA . This shall only be used to determine DP if
NOTE: Any consistent system of units may be used. the value of the resulting overstrain ratio so determined
is less than 0.4.
KD-521.1 When Outside Strain Is Known. If ⑀m
KD-510 LIMITS ON AUTOFRETTAGE
is measured, calculate DP /DO as follows.
PRESSURE
(a) For vessels supporting end load during auto-
There is no specified upper limit on autofrettage frettage,
pressure. However, the permanent tangential strain at
the bore surface resulting from the autofrettage operation
shall not exceed 2%.
冤
(DP /DO)2 p E⑀m + ␯
冢 PAD2I
D2O − D2I 冣冥冫
1.15Sy

KD-520 CALCULATION OF RESIDUAL (b) For all other cases,

STRESSES
(a) In order to evaluate the design of a vessel (DP /DO)2 p [E⑀m + ␯ (F1 /Acs)] /1.15Sy
utilizing autofrettage, a calculation of the residual stress
distribution produced by autofrettage shall first be per-
formed. This calculation requires knowledge of the KD-521.2 When Residual Inside Strain Is Known.
actual extent of autofrettage obtained during the process. If ⑀p is measured, calculate DP from the following
This is defined by the diameter of the elastic–plastic equation using an iterative procedure:
interface DP or by the overstrain ratio (DP − DI) /(DO
− DI). Possible methods for determining DP are given 2E⑀p /1.15Sy p (1 − 2␯)[ln(DI /DP)2 − 1] + (2 − ␯)(DP /DI)2
below. Other methods may be used if they can be
shown to be more accurate or conservative.
+ (1 − ␯)(DP /DO)2
(b) Machining after autofrettage is permitted. The
resulting extent of autofrettage (overstrain ratio) for
this condition is calculated using the final dimensions
of the vessel and the assumption that DP remains as
[ln(DP /DI)2 + (D2O − D2P) /D2O] [1 − ␯ + (1 + ␯)Y 2]
determined above. However, any residual tensile stresses −
Y2 − 1
introduced by the machining shall be considered.
(c) The theoretical residual stresses calculated in this
Article are based on the maximum shear criterion
KD-521.3 When Autofrettage Pressure Is Known.
and the assumption that the longitudinal stress is the
If PA is measured and the requirements of KD-521(c)
intermediate principal stress. Therefore, the residual
are met, then DP can be determined from the following
longitudinal stress distribution cannot be determined by
equation using an iterative procedure:
this theory. In most pressure vessel applications, the
longitudinal stress in the cylinder wall, remote from
discontinuities, is the intermediate principal stress and PA p 1.15Sy [ln(DP /DI) + (D2O − D2P) /2D2O]

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 KD-522 2001 SECTION VIII — DIVISION 3 KD-530

KD-522 Residual Stresses Between Bore and (d) For DI < D < DZ , calculate the residual stress
Elastic–Plastic Interface distribution from Eqs. (1) and (2):
The general method for calculating the autofrettage
residual stresses is given below for a monobloc cylinder. ␴tR D [ln(D /DI) + 1] + DI − 2D
p Z (1)
␴CD D Z − DI
KD-522.1 When No Reverse Yielding Occurs. Cal-
culate the first approximation of the tangential and
radial residual stress distributions (␴tRA and ␴rRA) using ␴rR D ln (D /DI) + DI − D
p Z (2)
Eqs. (1) and (2) for DI < D < DP . ␴CD DZ − DI

(e) For D > DZ , the residual stresses shall be corrected

冢 冣
␴tRA D 2 + D2 D
p P 2 O + ln to ensure that continuity and equilibrium conditions
1.15Sy 2DO DP
are met. This shall be accomplished by calculating a
correction factor Fb as follows.
冤D 冥冤 冢 冣冥 冢 冣
D2I D2O − D2P DP D2O
− + ln 1+ (1) (1) Calculate ␴rR at D p DZ using Eq. (2) above.
2
− D2I 2D2O DI D2
O (2) Calculate ␴rRA at D p DZ using Eq. (2) in
KD-522.1.
(3) Divide the results of subparagraph (1) by the
冢 冣
␴rRA D2 − D 2 D
p P 2 O + ln results of subparagraph (2) and this equals Fb .
1.15Sy 2DO DP
(f) For DZ < D < DP , calculate the residual stresses
using Eqs. (1) and (2) in KD-522.1 and multiply the
冤D 冥冤 冢 D 冣冥 冢1 − D 冣
D2I D2O − D2P DP D2O
− 2
+ ln (2) results at each value of D by Fb .
O − D2I 2D2O I 2

KD-523 Residual Stresses Between Elastic–

KD-522.2 Correction for Reverse Yielding Plastic Interface and Outside
(Bauschinger Effect). Calculate the value of ␴tRA at Diameter
D p DI from Eq. (1) in KD-522.1 and define this as For DP < D < DO , calculate the residual stresses
␴AD . If ␴AD/Sy is more negative than −0.4, then the using Eqs. (1) and (2):
residual stress distribution shall be corrected for the
fact that reverse yielding will occur on unloading from

冢 冣 冦2D
the autofrettage pressure due to the reduction of the ␴tR D2 D2P D2I
p Fb 1 + O2 +
compressive strength of the material resulting from 1.15Sy D 2
O D2O − D2I
tensile plastic deformation. This is known as the
Bauschinger effect. If ␴AD/Sy is more positive than
冤 冢 D 冣冥冧
D2P − D2O DP
−0.4, then no correction is required and the residual × − ln (1)
2D2O I
stresses calculated from Eqs. (1) and (2) in KD-522.1
shall be used for design for DI < D < DP . For DP <
D < DO , Eqs. (1) and (2) in KD-523 with Fb p 1.0
冢 冣 冦2D
␴rR D2 D2P D2I
p Fb 1 − O2 +
shall be used. 1.15Sy D 2
O D2O − D2I
When ␴AD/Sy is more negative than −0.4, a correction
to ␴tRA and ␴rRA shall be made as follows.
冤 冢 D 冣冥冧
D2P − D2O DP
(a) Using Eqs. (1) and (2) in KD-522.1, calculate × − ln (2)
the value of D at which (␴tRA − ␴rRA) /Sy p 0 using 2D2O I

an iterative procedure, and define this as DZ .

(b) Calculate a corrected value of the residual tangen-
tial stress at D p DI (defined as ␴CD) from:
KD-530 DESIGN CALCULATIONS
␴CD /Sy p −0.4 + 0.5(␴AD /1.15Sy + 0.4) These residual stress values are used in the fatigue
analysis as described in Article KD-3 and in the fracture
(c) If ␴CD /Sy < −0.7, then let ␴CD /Sy p −0.7. mechanics analysis as described in Article KD-4.

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