Autofrettage is used to introduce advantageous residual stresses into pressure vessels and to enhance their fatigue lifetimes. The Bauschinger effect serves to reduce the yield strength in compression as a result of prior tensile plastic overload and can produce lower compressive residual hoop stresses near the bore than are predicted by “ideal” autofrettage solutions (elastic/perfectly plastic without Bauschinger effect). A complete analysis procedure is presented which encompasses representation of elastic-plastic uniaxial loading material behavior and of reverse-loading material behavior as a function of plastic strain during loading. Such data are then combined with some yield criterion to accurately predict elastic-plastic residual stress fields within an autofrettaged thick cylinder. Pressure for subsequent reyielding of the tube is calculated. The numerical procedure is further used to determine residual stress fields after removal of material from inside diameter (i.d.) and/or outside diameter (o.d.), including the effects of any further plasticity. A specific material removal sequence is recommended. It is shown that Sachs’ experimental method, which involves removing material from the i.d., may very significantly overestimate autofrettage residual stresses near the bore. Stress ranges and stress intensity factors for cracks within such stress fields are calculated together with the associated fatigue lifetimes as such cracks propagate under cyclic pressurization. The loss of fatigue lifetime resulting from the Bauschinger effect is shown to be extremely significant.

Issue Section:
Research Papers
Topics:
Autofrettage, Design, Stress, Fatigue, Fracture (Materials), Residual stresses, Compression, Cylinders, Hoop stress, Plasticity, Pressure, Pressure vessels, Yield strength
1.
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2.
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Parker
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,
1984
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Dimensionless Stress Intensity Factors for Cracked Thick Cylinders Under Polynomial Crack Face Loadings
,”
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4.
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5.
Chakrabarty, J., 1987, Theory of Plasticity, McGraw Hill, New York, NY.
6.
Chen
P. C. T.
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1986
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The Bauschinger and Hardening Effect on Residual Stresses in an Autofrettaged Thick-Walled Cylinder
,”
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7.
Davidson, T. E., Kendall, D. P., and Reiner, A. N., 1963, “Residual Stresses in Thick-walled Cylinders Resulting from Mechanically Induced Overstrain,” Experimental Mechanics, pp. 253–262.
8.
Jahed
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An Axisymmetric Method of Elastic-Plastic Analysis Capable of Predicting Residual Stress Field
,”
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9.
Kendall, D. P., 1987, “The Influence of the Bauschinger Effect on Re-yielding of Autofrettaged Thick-Walled Cylinders,” ASME PVP-Vol. 125, pp. 17–21.
10.
Kendall, D. P., 1998, Discussion of paper “The Bauschinger Effect in Autofrettaged Tubes—A Comparison of Models Including the ASME Code,” by A. P. Parker and J. H. Underwood, Proceedings, ASME Pressure Vessels & Piping Conference, San Diego, CA.
11.
Megahed
M. M.
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Abbas
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,
1991
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Influence of Reverse Yielding on Residual Stresses Induced by Autofrettage
,”
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12.
Milligan, R. V., Koo, W. H., and Davidson, T. E., 1966, “The Bauschinger Effect in a High Strength Steel,” TRANS. ASME, Series D, pp. 480–488.
13.
Paris
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A Critical Analysis of Crack Propagation Laws
,”
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14.
Parker, A. P., Sleeper, K. A., and Andrasic, C. P., 1981, “Safe Life Design of Gun Tubes—Some Numerical Methods and Results,” Proceedings, U.S. Army Numerical Analysis and Computers Conference, pp. 311–333.
15.
Parker, A. P., and Underwood, J. H., 1998, “Influence of the Bauschinger Effect on Residual Stress and Fatigue Lifetimes in Autofrettaged Thick Walled Cylinders,” Fatigue and Fracture Mechanics: 29th Volume, ASTM STP 1321, T. L. Panontin and S. D. Sheppard, eds.
16.
Weiss, V., 1956, “Residual Stresses in Cylinders,” Syracuse University Research Institute Report No. MET 345-563T2, Syracuse, NY.
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