Acoustic Fatigue Evaluation of Branch Connections

Author(s):  
Dan Lin ◽  
Ajay Prakash ◽  
Philip Diwakar ◽  
Bertito David

High acoustic energy is known to cause vibrations in pipes, and in some severe cases acoustic induced vibration can lead to fatigue failure at branch connections with high stress concentration. Industry guidelines suggest using mitigation measures such as fabricated full wrap-around reinforcement pad (re-pad) or Sweepolet fittings at branch connections. Effectiveness of these mitigation measures is evaluated via a finite element analysis of four types of branch connections; (i) Sockolet, (ii) Sockolet with 2″ wide partial re-pad, (iii) Sockolet with full wrap-around re-pad, and (iv) Sweepolet. Four distinct acoustic frequency ranges (1/3 octave bands) with associated sound pressure levels are used as the excitation source. Maximum stress levels in the main header pipe at the branch tie-in are monitored to assess the potential for vibration damage. Of the four branch connections, Sockolet with full wrap-around re-pad is found to be least susceptible to damage, followed by the Sweepolet. Unreinforced Sockolet is most susceptible to damage, and the Sockolet with partial re-pad is only marginally better.

Author(s):  
Yuqing Liu ◽  
Philip Diwakar ◽  
Dan Lin ◽  
Ismat Eljaouhari ◽  
Ajay Prakash

High acoustic energy has the potential to cause severe Acoustic Induced Vibration (AIV) that leads to fatigue failure at high stress concentration regions such as fittings in a piping system. Sweepolet fittings have been extensively used as mitigation to counteract the risk of fatigue failure caused by AIV. The advantages of a sweepolet are its integrally reinforced contoured body and low stress concentration. However, there are inconsistencies in published standards and regarding the design limits for sweepolet subjected to AIV. In this paper, Finite Element Analysis is conducted to simulate high frequency pipe shell wall vibration caused by acoustic energy inside the pipe. Peak stress and the associated minimum fatigue life are calculated for sweepolet and sockolet under the same acoustic excitation. By comparing the stress level to that of a sockolet whose design limit to AIV had been published, the design curve and fatigue life equation for sweepolet are developed.


Author(s):  
Ajay Prakash ◽  
Philip Diwakar ◽  
Dan Lin ◽  
Paul Deane ◽  
Yuqing Liu ◽  
...  

High acoustic energy has the potential to cause severe acoustic induced vibration (AIV) that can lead to fatigue failure at high stress concentration locations (discontinuities) in a piping system. AIV at pipe junctions (Lateral, Tee, and Wye) and welded support attachments (trunnions and shoes) is evaluated using Finite Element Analysis. At different size pipe junctions, branch and header pipe shells may be subjected to different sound pressure. Also, inertia associated with different wall thickness(s) can lead to very different dynamic response of the two shell walls. The effect of these differences on AIV response is analyzed. Resulting response for different junction reinforcement designs is evaluated and compared to an unreinforced ‘stub-on’ configuration to assess the designs.


Energies ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 4711
Author(s):  
Armanto P. Simanjuntak ◽  
Jae-Young Lee

Printed circuit heat exchangers (PCHEs) are often subject to high pressure and temperature difference between the hot and cold channels which may cause a mechanical integrity problem. A conventional plate heat exchanger where the channel geometries are semi-circular and etched at one side of the stacked plate is a common design in the market. However, the sharp edge tip channel may cause high stress intensity. Double-faced type PCHE appears with the promising ability to reduce the stress intensity and stress concentration factor. Finite element analysis simulation has been conducted to observe the mechanical integrity of double-etched printed circuit heat exchanger design. The application of an additional ellipse upper channel helps the stress intensity decrease in the proposed PCHE channel. Five different cases were simulated in this study. The simulation shows that the stress intensity was reduced up to 24% with the increase in additional elliptical channel radius. Besides that, the horizontal offset channels configuration was also investigated in this study. Simulation results show that the maximum stress intensity of 2.5 mm offset configuration is 9% lower compared to the maximum stress intensity of 0 mm offset. This work proposed an additional elliptical upper channel with a 2.5 mm offset configuration as an optimum design.


1991 ◽  
Vol 113 (3) ◽  
pp. 398-401 ◽  
Author(s):  
A. Chaaban ◽  
U. Muzzo

Due to the high stress concentration at the root of the first active thread in threaded end closures of high pressure vessels, yielding may occur in this region during the application of the first pressure cycle or proof testing. This overstraining introduces residual stresses that influence the fatigue performance of the vessel. This paper presents a parametric analysis of threaded end closures using elastic and elasto-plastic finite element solutions. The results are used to discuss the influence of these residuals on the estimated fatigue life when the vessel is subjected to repeated internal pressure. A simple empirical method to allow for the Bauschinger effect of the material is also proposed.


2013 ◽  
Vol 658 ◽  
pp. 345-349
Author(s):  
Il Taek Lee ◽  
Hyun Sik Kim ◽  
Namr Young Choi ◽  
Dong Pyo Hong

Recently, due to the rising of oil prices, interest in FCC Unit (Fluid Catalytic Cracking Unit) energy recycling is increasing. FCC Unit (Fluid Catalytic Cracking Unit) is a mechanical used to convert bunker C oil into high quality gasoline. Pressure vessel of FCC Unit is that refining the crude oil when is operating in high-temperature and high-pressure environment. So it needs analysis of structure carefully. In this paper, FEA (Finite element analysis) of the FCC unit was performed to evaluate its structural stability and weight reduction. The equivalent stress of the FCC unit was investigated and compared against the ASME code design specifications. The area of high stress concentration with maximum stress higher than the prescribed value was analyzed locally to carefully evaluate the stress. Finally, we were reduces the thickness of the CA nozzle in FCC unit, and it was satisfied structural stress.


2014 ◽  
Vol 627 ◽  
pp. 337-340
Author(s):  
Wouter de Corte ◽  
Arne Jansseune

Complex welded structures such as bridges are very often designed with the help of FE analysis. However, one should remain cautious when using such an analysis, since the results are mesh sensitive, with especially the mesh density and the element type influencing the results. In addition, these results are in most cases retrieved in hot spot areas with high stress gradients, where the maximum stress even cannot be correctly determined with linear elastic finite element analysis. For that reason, a stress evaluation method is required to obtain relevant stress levels that can be directly related to fatigue detailing. The most complete set of stress evaluation recommendations is given in the Recommendations for Fatigue Design of Welded Joints and Components from the International Institute of Welding. Nevertheless, several authors have recently commented on the difficulties regarding the application of these methods for the rib to floorbeam welds in orthotropic bridge decks. This paper provides findings for this type of connections based on both shell and solid model analysis and relates these findings to work from other authors.


2016 ◽  
Vol 37 (12) ◽  
pp. 1343-1349 ◽  
Author(s):  
Kamran S. Hamid ◽  
Aaron T. Scott ◽  
Benedict U. Nwachukwu ◽  
Kerry A. Danelson

Background: In 1976, Ramsey and Hamilton published a landmark cadaveric study demonstrating a dramatic 42% decrease in tibiotalar contact area with only 1 mm of lateral talar shift. An increase in maximum principal stress of at least 72% is predicted based on these findings though the delayed development of arthritis in minimally misaligned ankles does not appear to be commensurate with the results found in dry cadaveric models. We hypothesized that synovial fluid could be a previously unrecognized factor that contributes significantly to stress distribution in the tibiotalar joint in anatomic and injured states. Methods: As it is not possible to directly measure contact stresses with and without fluid in a cadaveric model, finite element analysis (FEA) was employed for this study. FEA is a modeling technique used to calculate stresses in complex geometric structures by dividing them into small, simple components called elements. Four test configurations were investigated using a finite element model (FEM): baseline ankle alignment, 1 mm laterally translated talus and fibula, and the previous 2 bone orientations with fluid added. The FEM selected for this study was the Global Human Body Models Consortium–owned GHBMC model, M50 version 4.2, a model of an average-sized male (distributed by Elemance, LLC, Winston-Salem, NC). The ankle was loaded at the proximal tibia with a distributed load equal to the GHBMC body weight, and the maximum principal stress was computed. Results: All numerical simulations were stable and completed with no errors. In the baseline anatomic configuration, the addition of fluid between the tibia, fibula, and talus reduced the maximum principal stress computed in the distal tibia at maximum load from 31.3 N/mm2 to 11.5 N/mm2. Following 1 mm lateral translation of the talus and fibula, there was a modest 30% increase in the maximum stress in fluid cases. Qualitatively, translation created less high stress locations on the tibial plafond when fluid was incorporated into the model. Conclusions: The findings in this study demonstrate a meaningful role for synovial fluid in distributing stresses within the ankle that has not been considered in historical dry cadaveric studies. The increase in maximum stress predicted by simulation of an ankle with fluid was less than half that projected by cadaveric data, indicating a protective effect of fluid in the injured state. The trends demonstrated by these simulations suggest that bony alignment and fluid in the ankle joint change loading patterns on the tibia and should be accounted for in future experiments. Clinical Relevance: Synovial fluid may play a protective role in ankle injuries, thus delaying the onset of arthritis. Reactive joint effusions may also function to additionally redistribute stresses with higher volumes of viscous fluid.


2003 ◽  
Vol 125 (3) ◽  
pp. 392-399 ◽  
Author(s):  
T. Y. Lin ◽  
Z. P. Xiong ◽  
Y. F. Yao ◽  
Lane Tok ◽  
Z. Y. Yu ◽  
...  

There has been significant demand for stacked die technology during the past few years. The stacked die devices are mainly used in portable consumer products. This kind of silicon integration technology provides flexibility in space reduction, weight savings, and excellent electrical functionality. In this article, the stacked die construction was built into the leaded package. It was found that the test vehicles had full delamination at the lead-frame paddle/mold compound interface after 100 temperature cycles (−65°C to 150°C) with moisture preconditioning at level 3 (60°C at 60% relative humidity for 40 h) although the electrical test passed 1000 temperature cycles. The fishbone diagram was used to identify the possible failure root causes. The material, process, and design factors were extensively evaluated by the experiments and finite element analysis. The evaluation results showed that die attach paste voids were major factors affecting the package integrity and could produce the delamination initiation at the edge of the die attach paste and propagate down to the lead-frame paddle/mold compound interface due to high stress concentration and weak adhesion strength. The finite element analyses were implemented to address the stress distribution in the stacked die package and verified by the scanning acoustic microscope. It demonstrated that excellent package integrity could be obtained by applying the void-free die attach paste and improving the adhesion strength at the lead-frame paddle level.


Author(s):  
Yucheng Yang ◽  
Qin Ma

Abstract Pedicle screws (PS) are frequently used in medical spinal column fixation. Despite 7 out of 100 pedicle screws fracture inside of the patients’ body and under the claim that lateral bending is the main failure mode, little research has addressed the stress characteristics and the fracture location of the PS under lateral bending. This study focuses on the effect of thread design on the magnitude and location of maximum stress concentration. Four types of thread shapes are considered including V-shape, square-shape, buttress, and reverse buttress. Three-dimensional (3D) finite element (FE) methods are used in this investigation. A load of 150 Newton is applied at the screw head to simulate lateral bending. The models are created in SolidWorks. The 3D FE analysis is performed using the standard coding of ANSYS Workbench 19.1. Based on this study, it is found that the high stress concentration is located at the cortical bone region rather than at the cancellous bone region. Although the general stress patterns are similar, the PS thread shape design and the thread fillet radius may significantly affect on the magnitude and location of maximum stress concentration.


Author(s):  
S Mathukumar ◽  
VA Nagarajan ◽  
A Radhakrishnan

Humans face bone fracture when they unfortunately met an accident, which requires timely medical attention for healing and repairing the fractured bone; otherwise that paralyzes their life. 3D modeling technique with computational method is very helpful at the side of doctors for healing and repairing the damaged bones. Fractional bone healing is one of the natural processes, which regain the mechanical reliability of the bone to a limited level of failures. The relationship between the biology and mechanics has introduced a new branch namely biomechanics. Various biomechanics models were used to identify the fracture for different patients and helps in the fracture treatment. The aim of this work is to find out the high stress concentration area of the femur bone, which has been extracted as image from computer tomography scanner. The retrieved noise-free femur bone image is tested by the static load condition with the help of the finite element analysis. The result obtained from the testing of different loads has been compared with the existing literature. It is found that the femur bone has tensile and compressive stress, and the neck area of the femur is at a very high stress concentration. The outcome of this work is much supportive to orthopedic surgeons in femur surgery and bone prosthesis by avoiding experiments on femur bone.


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