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Pressure Limits of Thick-Walled Cylinders

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Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II
IMECS 2009, March 18 - 20, 2009, Hong Kong

Pressure Limits of Thick-Walled Cylinders

A. B. Ayob, M. N. Tamin, and M. Kabashi Elbasheer

developed to a certain radial depth at the bore. These residual

Abstract— The effect of autofrettage on thick-walled stresses serve to reduce the tensile stresses developed as a
cylinders, operating under high internal pressure, has become a result of subsequent application of an operating pressure,
significant area of development, both in research and practice. thus increasing the load bearing capacity [1, 2]. Usually large
In optimal design of thick-walled cylinders, there are two main
objectives to be achieved: increasing its strength-weight ratio
scale yielding occurs in the autofrettaged thick-walled
and extending its fatigue life. This can be achieved by cylinder wall [3]. Theoretical and numerical methods used to
generating a residual stress field in the cylinder wall prior to determine limit loads involve some assumptions and
use. Both analytical and numerical techniques have been used parameters that affect the accuracy of the results. The
for the investigation of the effects of residual stresses on the purpose of this study is to investigate the effect of
load-carrying capacity. The scope of the current paper includes autofrettage parameters on the limit loads. The simplest and
application of ABAQUS finite element code to the direct
problem of finding thick-walled cylinder autofrettage solutions.
most general theoretical treatment of the partially-plastic
The results reveal three scenarios in the design of thick-walled cylinder has been the use of the Tresca yield criterion, with
cylinders. For maximum load carrying capacity, the assumption of an elastic perfectly-plastic material. Using
non-autofrettage is suitable when, in service, the whole wall the Tresca yield criteria together with an autofrettage level
thickness will be yielded. Full autofrettage is suitable when, parameter, a precise solution for residual stress was
during subsequent operation, yielding is limited at the inner developed.
surface. Optimum autofrettage of the cylinder is suitable if a
minimum equivalent stress is to be achieved. The analytical
solutions were compared to numerical results and a very good
correlation in form and magnitude was obtained. II. OPERATING PRESSURE LIMITATIONS
For a cylinder subjected to an internal pressure, Pi , the
Index Terms— Autofrettage, elastic-plastic junction line, radial stress, σr , and circumferential (hoop) stress, σθ ,
finite element analysis, loads capacity, residual stress.
distributions are given by Lame’s formulation:
P ⎡ r ⎤
2
σr = 2 i ⎢1− o2 ⎥ (1)
I. INTRODUCTION k −1 ⎣ r ⎦
Due to the ever-increasing industrial demand for P ⎡ r ⎤
2
σθ = 2 i ⎢1+ o2 ⎥ (2)
axisymmetric pressurized cylindrical components which k −1 ⎣ r ⎦
have had wide applications in chemical, nuclear, fluid
transmitting plants, power plants and military equipment, the
attention of designers has been concentrated on this For a cylinder with end caps and free to change in length,
particular branch of engineering. The increasing scarcity and the axial stress is given by [5]:
higher cost of materials have led researchers not to confine P (3)
σz = 2 i
themselves to the customary elastic regime but moved their k −1
attention to the elastic–plastic approach which offers more where k = ro (4)
efficient use of materials [4]. Autofrettage is a common ri
process of producing residual stresses in the wall of a
thick-walled cylinder prior to use. An appropriate pressure, According to Tresca yield theory, yielding occurs when
large enough to cause yielding within the wall, is applied to the equivalent stress is [5]:
the inner surface of the cylinder and then removed. Upon σ Tr = (σ θ − σ r ) = σ Y
(5)
release of this pressure, compressive residual stresses are
Two important pressure limits, PY,i and PY,o , are
Manuscript received November 11, 2008.
considered to be of importance in the study of pressurized
A. B. Ayob is with the Faculty of Mechanical Engineering, Universiti cylinders. PY,i corresponds to the internal pressure required at
Teknologi Malaysia, 81310 UTM Skudai, Johor, MALAYSIA, (Tel: the onset of yielding of the inner surface of the cylinder, and
+607-5534580, Fax: +607-5566159, e-mail: [email protected]) PY,o is the internal pressure required to cause the whole wall
M. N. Tamin is with the Faculty of Mechanical Engineering, Universiti
Teknologi Malaysia, 81310 UTM Skudai, Johor, MALAYSIA, (Tel: to yield completely. The magnitudes of PY,i and PY,o ,
+607-5534580, Fax: +607-5566159, e-mail: [email protected]) according to Tresca yield strength criterion, are [1, 6 and 7]:
M. Kabashi Elbasheer (Member of IAENG) is a PhD student at the For PY,i :
Faculty of Mechanical Engineering, Universiti Teknologi Malaysia, 81310
UTM Skudai, Johor, MALAYSIA. He is on leave from the Sudan University
of Science and Technology, Khartoum, Sudan (Tel: +601-77243822, e-mail:
pi
k −1
2
(1 + k 2 ) - 2 i (1 − k 2 ) = σ Y
p
k −1
[email protected]).

ISBN: 978-988-17012-7-5 IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II
IMECS 2009, March 18 - 20, 2009, Hong Kong

pi
k −1
2
( )
2k 2 = σ Y σ z,p,R =
σ Y ⎪⎧⎡ ⎛r⎞ m2 ⎤ ⎡ m2 ⎤⎛ 1 ⎞⎪⎫ (8.c)
⎨⎢1 + 2ln⎜⎜ ⎟⎟ − 1 + 2 ⎥ − ⎢2ln (m + 1) − 2 ⎥⎜ 2 ⎟⎬
2 ⎪⎩⎣ ⎝ ra ⎠ k ⎦ ⎣ k ⎦⎝ k − 1 ⎠⎪⎭
(k 2 − 1)
PTr, Y, i = σY For the elastic region, ra ≤ r ≤ ro
2k 2
σY ⎡ ro ⎤ ⎧ m 2 ⎛ ⎞ ⎛ 1 ⎞ ⎫ (9.a)
2
m2
P Tr, Y, i (k 2 − 1) (6) σ r, e, R = ⎢1 − 2 ⎥ ⎨ 2 − ⎜⎜ 1 − 2 + 2ln (m )⎟⎟ ⎜ 2 ⎟⎬
= 2 ⎣ r ⎦⎩ k ⎝ k ⎠⎝ k − 1 ⎠ ⎭
σY 2k 2
Eqn. (6) is the non-dimensionalized inner surface pressure
⎡ ro ⎤ ⎧ m 2 ⎛ ⎞ ⎛ 1 ⎞ ⎫ (9.b)
2
σY m2
limit of thick-walled cylinder using Tresca yield criterion. σ θ, e, R = ⎢1 + 2 ⎥ ⎨ 2 − ⎜⎜ 1 − 2 + 2ln (m )⎟⎟ ⎜ 2 ⎟⎬
As for PY,o : 2 ⎣ r ⎦⎩ k ⎝ k ⎠⎝ k − 1 ⎠ ⎭
2 pi
= σY
k2 −1 σY ⎧m2 ⎛ m2 ⎞⎛ 1 ⎞ ⎫ (9.c)
σ z, e, R = ⎨ 2 − ⎜⎜ 1 − 2 + 2ln (m )⎟⎟⎜ 2 ⎟⎬
(k 2 − 1) 2 ⎩k ⎝ k ⎠⎝ k − 1 ⎠ ⎭
PTr, Y, o = σY
2
P Tr, Y, o (k 2 − 1) (7) where m = ra (10)
=
σY 2 ri
Eqn. (7) corresponds to the outer surface pressure limit. The and ra is the autofrettage radius. By substituting r = ra, the
relationships between PTr,Y,i and PTr,Y,o with ro and ri are residual stresses at junction radius, ra , is obtained.
graphically shown in Fig. 1.
σY ⎡ k 2 ⎤⎧ m 2 ⎛ m2 ⎞⎛ 1 ⎞ ⎫ (11.a)
σ r, R = ⎢1 − 2 ⎥ ⎨ 2 − ⎜⎜ 1 − 2 + 2ln (m )⎟⎟⎜ 2 ⎟⎬
2 ⎣ m ⎦⎩ k ⎝ k ⎠⎝ k − 1 ⎠ ⎭

σY ⎡ k 2 ⎤⎧ m2 ⎛ m2 ⎞⎛ 1 ⎞ ⎫ (11.b)
σ θ, R = ⎢1 + 2 ⎥ ⎨ 2 − ⎜⎜1 − 2 + 2ln (m )⎟⎟⎜ 2 ⎟⎬
2 ⎣ m ⎦⎩ k ⎝ k ⎠⎝ k − 1 ⎠ ⎭

σY ⎧ m2 ⎡ m2 ⎤⎛ 1 ⎞⎫ (11.c)
σ z, R = ⎨ 2 − ⎢1 − 2 + 2ln (m )⎥ ⎜ 2 ⎟⎬
2 ⎩k ⎣ k ⎦⎝ k − 1 ⎠⎭

The plot of the above residual stress distributions are

shown in Fig. 2. On application of the operating pressure the
total stress of the partially autofrettaged cylinder is the
summation of the residual stress and the stress due to the
operating pressure, i.e.:

Fig. 1: Pressure limits of thick-walled cylinder σr,T = σr +σr,R (12.a)

σθ,T = σθ + σθ,R (12.b)
σ z,T = σ z + σ z, R (12.c)
III. AUTOFRETTEGE PROCESS
The autofrettage pressure, Pa , is a sufficiently high internal
pressure applied before a cylinder is put into use. If the
internal pressure is removed after part of the cylinder
thickness has become plastic, a residual stress is set up in the
wall. Assuming that during unloading the material follows
Hooke’s Law; the residual stresses can be obtained from
equations [8]:
For the plastic region, ri ≤ r ≤ r a
σY ⎧⎪⎡ ⎛ r ⎞ m2 ⎤ ⎡ m2 ⎤⎛ 1 ⎞⎛ ro ⎞⎫⎪
2
σ r,p,R = ⎨⎢2ln⎜⎜ ⎟⎟ − 1 + 2 ⎥ − ⎢2ln (m + 1) − 2 ⎥⎜ 2 ⎟⎜⎜1 − 2 ⎟⎟⎬
2 ⎪⎩⎣ ⎝ ra ⎠ k ⎦ ⎣ k ⎦⎝ k − 1 ⎠⎝ r ⎠⎪⎭
(8.a)

σY ⎧⎪⎡ ⎛r⎞ m2 ⎤ ⎡ m2 ⎤⎛ 1 ⎞⎛ ro ⎞⎫⎪

2
σθ,p,R = ⎨⎢2 + 2ln⎜⎜ ⎟⎟ −1 + 2 ⎥ − ⎢2ln (m + 1) − 2 ⎥⎜ 2 ⎟⎜⎜1 + 2 ⎟⎟⎬
2 ⎪⎩⎣ ⎝ ra ⎠ k ⎦ ⎣ k ⎦⎝ k −1 ⎠⎝ r ⎠⎪⎭
(8.b) Fig. 2: Residual stress distributions, after autofrettage

ISBN: 978-988-17012-7-5 IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II
IMECS 2009, March 18 - 20, 2009, Hong Kong

The comparison of total stress distributions between

autofrettaged and non-autofrettaged cylinders is shown in
Fig. 3. In operation, autofrettage causes the high hoop stress
at the inner surface to be reduced, and moves the location of
the peak hoop stress from the inner surface to a location r = ra.
The equivalent stresses at r = ra is a maximum value.

Fig. 4: Total Tresca equivalent stress

The internal pressure to cause yielding to a depth of r is:

σY ⎡ r2 ⎛ r ⎞⎤ (15)
P= ⎢1 − 2 + 2ln⎜⎜ ⎟⎟⎥
2 ⎢⎣ ro ⎝ ri ⎠⎥⎦

From Eqn. (14) the optimum autofrettage radius is obtained:

ra, opt = ri e n
Fig. 3: Total stress distributions of autofrettaged and
Therefore the optimum autofrettage pressure is:
non-autofrettaged cylinders σY ⎡ e2n ⎤
Pa,opt,Tr = (16)
⎢1− 2 +2n⎥
2⎣ k ⎦
The autofrettage process leads to a decrease in the
maximum Tresca equivalent stress during the working stage. Using an arbitrary value of autofrettage pressure the total
This means that the cylinder can now be subjected to an Tresca equivalent stress, using Eqns. 1-3 and Eqns. 8-12, can
increase in the pressure capacity. A key problem in the be found for all values of r. The equivalent stress is a
analysis of autofrettage is to determine the optimum maximum at all values of r=ra, but with P=Popt,a , the
autofrettage pressure and the corresponding radius of the maximum equivalent stress has a minimum value but is still
elastic–plastic boundary where the maximum equivalent lower than that in non-autofrettaged condition, as shown in
stress in the cylinder becomes a minimum. Fig. 4. The analytical results can be validated by numerical
analysis, as shown in Fig. 5.

IV. OPTIMUM AUTOFRETTAGE

During autofrettage, the cylinder is yielded to the
elastic-plastic junction line, called the autofrettage radius ra.
Using Tresca yield theory the equivalent stress at r = ra is
obtained, when the cylinder is subjected to internal operating
pressure, after being treated by autofrettage:
k2 ⎡ m2 ⎛ m2 ⎞ 1 ⎤ ⎡ 2Popr ⎤⎛ k 2 ⎞
σ Tr = σ Y ⎢ 2 − ⎜⎜1 − 2 + 2ln(m)⎟⎟ 2 ⎥ + ⎢ 2 ⎥⎜⎜ 2 ⎟⎟
m2 ⎣k ⎝ k ⎠ k − 1⎦ ⎣ k − 1⎦⎝ m ⎠ (13)

Differentiating and equating the differential to zero, i.e.

d σ Tr
= 0
dm
Hence, m = exp( Popr ) is obtained.
σY
Letting , n = Popr
σY
Therefore, m Tr = exp (n ) (14)
Fig. 5: Optimum autofrettage pressure and radius, from FEM

V. ALLOWABLE INTERNAL PRESSURE OF AUTOFRETTAGED

CYLINDER
Eqns. (6) and (7) are used to obtain the maximum internal

ISBN: 978-988-17012-7-5 IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II
IMECS 2009, March 18 - 20, 2009, Hong Kong

pressure to cause different stages of yielding in a cylinder

which is not treated with autofrettage. For a cylinder treated
with autofrettage, and using Tresca yield criterion, the
internal pressure to cause the inner surface to yield again, can
be obtained. Substituting Eqns. (1), (2) and (8) into Eqn. (12),
when r = ri , the internal pressure to cause yielding at the inner
surface is:

σY ⎡ m2 ⎤ (17)
PY, i = ⎢ (2ln (m ) + 1 − 2 ⎥
2 ⎣ k ⎦

When r = ro , by substituting Eqns. (1), (2) and (9) into Eqn.

(12), the internal pressure to cause the whole wall thickness
to yield is,
Fig. 6: Internal pressure to cause the inner surface to yield,
PY, o
σ
[
= Y (2ln (m ) + k 2 − m 2
2
] (18) with different levels of optimum autofrettage.

The values of pressure in Eqns. (17) and (18) can be

graphically represented in Figs. 6 and 7, respectively. These VII. PRESSURE LIMITATION OF OPTIMUM AUTOFRETTAGE
pressures are influenced by different optimum autofrettage CYLINDER
levels which were obtained when an operating pressure was Rearranging Eqn. (16), the relation between the optimum
initially known. From Fig. 6, the internal pressure to cause autofrettage pressure and the operating pressure is:
yielding at the inner surface of a cylinder which is treated
with optimum autofrettage pressure is greater than that for a Pa,opt ⎡ k 2 − e 2n ⎤
= ⎢n + (20)
non-treated cylinder. On the other hand, the internal pressure ⎥
σY ⎣ 2k 2 ⎦
to cause full yielding in a cylinder which has been treated
with optimum autofrettage is lower than that which is
non-treated with autofrettage (Fig. 7). Fig. 9 shows that, increasing the operating pressure results
in an increase in the optimum autofrettage pressure. For high
radius ratio (k>5), increasing the cylinder thickness does not
VI. FULL AUTOFRETTAGE affect the magnitude of the optimum autofrettage pressure
significantly. For low radius ratio (k<3), decreasing the
A special case is when the cylinder is fully autofrettaged, cylinder thickness leads to a dramatic decrease in optimum
i.e. ra= ro. Therefore m = k and the equivalent stress at any autofrettage pressure.
radius can be obtained:

⎡ 2ln (k ) ⎛ r 2 ⎞ ⎤ 2Popr ⎛ r 2 ⎞ (19) Table 1: Allowable internal pressure of cylinder treated

σ Tr = σ Y ⎢1 − 2 ⎜ o ⎟⎥ + ⎜ o ⎟ = σY
⎢⎣ k − 1 ⎜⎝ r 2 ⎟⎠ ⎥⎦ k 2 − 1 ⎜⎝ r 2 ⎟⎠ with different levels of autofrettage.

Therefore the internal pressure to cause the internal

surface and whole thickness to yield is, by substituting r = ri
and r = ro into Eqns. (17) and (18) respectively. Table 1 and
Fig. 8 show the influence of autofrettage level pressure on the
allowable internal pressure of the cylinder, calculated
according to Tresca yield criterion. Comparisons of the
internal pressure are made between a cylinder which is not
treated with autofrettage, treated with optimum autofrettage
and full autofrettage.

ISBN: 978-988-17012-7-5 IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II
IMECS 2009, March 18 - 20, 2009, Hong Kong

Fig. 9: Optimum autofrettage for different values of

operating pressure and radius ratio.

VIII. FINITE ELEMENT ANALYSIS

The autofrettage process may be simulated by finite
element methods, making use of elastic-plastic analysis.
Using the ABAQUS code, an FE model of a cylinder with an
inside radius 100 mm and outside radius of 200 mm was
generated, as shown in Fig. 10(a). Symmetry conditions were
fully utilized to reduce computing time. The FE model
contained 30 elements and 62 nodes, as shown in Fig. 10(b).
The material used is steel which has the following properties:
E = 203 GPa
σY = 325 MPa
ν = 0.33
The material is assumed to be elastic-perfectly plastic,
having Tresca plasticity response.
Fig. 7: Internal pressure to cause the whole thickness to
yield, with different optimum autofrettage level.

Fig. 8: Allowable internal pressure of none, full and

optimum autofrettaged cylinder, using Tresca yield criteria

Fig. 10: Dimensions of plain thick-walled cylinder

axisymmetric model

ISBN: 978-988-17012-7-5 IMECS 2009

Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II
IMECS 2009, March 18 - 20, 2009, Hong Kong

An internal (autofrettage) pressure of 202 MPa was • The optimum autofrettage pressure is unique for a given
applied, and then removed. The residual stress distributions operating pressure.
were then evaluated in the thick-walled cylinder. Using • There are three cases in the design of pressurized
subsequent operating pressure of 160-220 MPa, FEM results thick-walled cylinder:
show that the total equivalent stress becomes a minimum • Non-autofrettage is suitable if yielding is allowed
value of 237 MPa at an operating pressure of 200 MPa, as throughout the cylinder wall thickness.
shown in Fig. 11. • Full autofrettage is suitable if yielding is allowed at the
inner surface only.
• Optimum autofrettage case is suitable if the maximum
equivalent stress is to be optimized.

REFERENCES
[1] J. Perry, J. Aboudi, “Elastic-plastic stresses in thick-walled cylinders”,
ASME J. Pressure Vessel Technology, Vol. 125, pp. 248-252, 2003.
[2] W. Zhao, R. Seshadri and R.N. Dubey, “On thick-walled cylinder
under internal pressure”, ASME J. Pressure Vessel Technology, Vol.
125, pp. 267-273, 2003.
[3] R. Thumser, J. W. Bergmann and M. Vormwald, “Residual stress fields
and fatigue analysis of autofrettage parts”, Int. J. Pressure Vessels
Piping, 79, No. 2, pp. 113-117, 2002.
[4] Wang Zhiqun, “Elastic-plastic fracture analysis of a thick-walled
cylinder”, Int. J. Pressure Vessels Piping, 63, pp. 165–168, 1995.
[5] R.L. Mott, Applied Strength of Materials, Prentice Hall, New Jersey,
Ohio, 2002.
[6] R. Hill, The Mathematical Theory of Plasticity, Oxford University
Press, 1967.
[7] A. Chaaban and N. Barake, “Elasto-plastic analysis of high pressure
vessels with radial cross bores”, High Pressure Technology, ASME
PVP, Vol. 263, pp. 67–123, 1993.
[8] Z. Wuxue and Z. Zichu, “An elastic-plastic analysis of autofrettage
thick-walled cylinders”, Proc. Int. Conf. on Non-Linear Mechanics,
Shanghai, pp. 663-667, 1985.
[9] M. Kabashi and A. B. Ayob, “Fatigue life of optimum autofrettaged
pressurized stepped thick walled cylinders”, World Engineering
Congress, International Conference on Mechanical and Aerospace
Engineering, Penang, Malaysia, 5 – 9 August 2007
[10] A. B. Ayob and M. Kabashi, “Fatigue life of pressurized thick walled
cylinders”, International Conference on Applied Mechanics and
Mechanical Engineering (AMME13), Cairo, Egypt, 27 - 29 May 2008.
Fig. 11: Occurrence of a minimum of the maximum
equivalent Tresca stress
NOMENCLATURE

P pressure
r radius
IX. CONCLUSION k outer to inner radius ratio
m autofrettage to inner radius ratio
Two-dimensional FE simulations of the thick-walled
n operating pressure to yield stress ratio
cylinder were carried out to validate the analytical optimum σ normal stress
autofrettage pressure and radius. The effects of autofrettage ν poisson’s ratio
level parameters on the pressure capacity of cylinders were E elastic modulus
i inner
studied. From the results of this study, the following points o outer
may be concluded. a autofrettage
• After autofrettage, the largest residual stress is the hoop r radial
θ hoop
stress which is compressive and occurs at the inner z axial
surface of the thick-walled cylinder. This is beneficial in Y yield
reducing the largest tensile hoop stress in subsequent p plastic
e elastic
repressurization with an internal operating pressure. opt optimum
• The total equivalent stress values increases from the inner opr operating
surface to the maximum value at the elastic-plastic Tr Tresca
R residual
autofrettage radius, and then decreases toward the outer T total
surface.
• The autofrettage process increases the allowable internal
pressure and elastic strength of a cylinder.
• The autofrettage process has a negligible effect on
increasing the pressure capacity which can cause the
whole cylinder wall to yield.

ISBN: 978-988-17012-7-5 IMECS 2009

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