Pressure Vessel Design and Analysis with Metal Matrix Composites using FEA

Transcription

1 Pressure Vessel Design and Analysis with Metal Matrix Composites using FEA B V S Srikanth 1 P Revathi 2 1,2, Department of Mechanical Engineering, Godavari Institute of Engineering and Technology, Rajahmundry, Andhra Pradesh, India. bvssrikanth@rediffmail.com Abstract: The improvement in the area of various types of composites revolutionized and brought many changes in the areas of engineering products, manufacturing processes, material processing for various applications, industrial equipment manufacturing, aerospace parts and vehicles manufacturing, defence applications, etc. Due to their light weight and high strength to weight ratio, their applications in the manufacturing of pressure vessels also increased but are limited to small-scale only due to the production cost of the composites. In order to produce the composites pressure vessels at effective cost which can meet the standards of the materials used for pressure vessel construction and to sustain at working conditions of pressure vessels such as high pressure and temperature this paper aims at modelling a pressure vessel and analyse the pressure vessel using the properties of the Ti MMC, Al MMC, X38CrMoV composites and alloys using simulation studies and Finite Element Analysis (FEA) and compare them with existing materials. The design of pressure vessel is carried out in Solidworks Part Design and the finite element analysis (FEA) and simulations are carried out in Solidworks Simulation. Keywords: Design, FEA, Matrix, Metal Matrix Composite, High temp Steel, Simulations I. Introduction With the increase in the development and rise in the growth of population, there is also rise in the power consumption and usage. The development of technology in the field of boilers and pressure vessels boiler shells have reached a fair maturity level in their technological. However, the increase in the rise of technology also increased the challenges in the design of boilers and pressure vessels. One of the biggest challenges is to design a pressure vessel for high-temperature applications which can withstand major boiler problems like stress corrosive cracking (SCC) and thermal losses due to conduction and convection phenomenon. Choosing the best material for a specific pressure vessel may progress toward becoming tedious and costly experimentation process because of impediments in boosting power plant framework productivity, meeting the execution necessities of the steam turbine control plant and innovative work in the metallurgy associated with it. In power plants in both thermal power plants and nuclear power plants pressure vessels and boiler shell applications are rising step by step as the requirement for power are being expanded with the development of the number of inhabitants in people. The advancement of pressure vessels and boiler shells have achieved a reasonable development level in their innovative. In any case, the biggest plan contemplations of boiler shells are the 198

2 geometry which ought to withstand and work at ideal working states of the boiler for longer periods by supporting the wear and tears caused because of sulphidation, stress corrosive, and so forth. The damaged boiler shell additionally influences the execution of power plant and now and again likewise brings about disastrous blasts which the world has seen ordinarily since the past. This project aims at modelling a geometry for pressure vessel which can operate at optimal conditions of Ultra-supercritical thermal power plants and analyse the design with advanced materials like Ti MMC, Al MMC, and X38CrMoV composites and alloys which can operate at high temperatures and resistive to sulphidation, slagging and corrosion and compare the results with alloy steel which is used in the production of pressure vessels currently in the market. II. Governing Equations The method used in the structural simulation analysis of designs in Solidworks Simulation is the Finite Element Analysis (FEA). Finite Element Analysis used in simulation packages or solvers generally comprises of three steps. They are as follows: A. Pre-processing: In this step, the finite element mesh for the designed model is developed and boundary conditions, material properties, and loads are applied to the designed model. B. Solution: In this step, the problem is solved for the given loads and boundary conditions. The results such as Von Mises stress, strain, displacements, thermal effects, etc., are obtained in this step. C. Post-processing: In this step, the results are visualized in the form of contours, deformed shapes, and plots. This step helps in the debugging, verification and validation of results. Figure 1 shows the flow chart of steps involved in finite element analysis. III. Material Properties High-temperature metal matrix materials and steel are the materials used in this study. The materials used are: A. Ti- MMC B. Al - MMC C. X38CrMoV

3 D. Steel Table 1 represents the material properties. Table 1 Properties Ti - MMC Al - MMC X38CrMoV 5-3 Steel Yield strength e e e e+08 Tensile strength Elastic modulus 1.05e e e e e e e e+11 Poisson's ratio Mass density kg/m 3 kg/m 3 kg/m 3 kg/m 3 Shear modulus e e e+010 8e+10 Thermal expansion coefficient 9e-06 /Kelvin 2.2e-05 /Kelvin 1.1e-005 /Kelvin 1.23e-05 /Kelvin IV. Methodology A. Design of Pressure Vessel: The pressure vessel is designed in Solidworks Part design and the modelled pressure vessel Solidworks Simulation is used to analyze the model. In Figure 2, pressure vessel design is represented in the standard isometric view. Fig. 2: Pressure vessel Isometric View Table 2 represents the volumetric properties of the models of the pressure vessel using Ti MMC, Al MMC, X38CrMoV 5-3, and Steel materials. 200

4 Design With Alloy Mass (kg) Table 2 Volume (m 3 ) Density (kg/m 3 ) Weight (N) Ti- MMC e+06 Al - MMC X38CrMoV e+06 Steel e+06 B. The meshing of models: Table 3 represents the type of mesh, element types used in the meshing, number of Jacobian points and type of solver used in the simulation analysis of pressure vessel in Solidworks Simulation software. Table 3 Mesh Type Solid mesh Mesh Element Type Tetrahedron Jacobian points 4 Solver type FFEPlus Meshing information in detail is given in this chapter in part c. C. Pressure Vessel detailed Meshing information: Tables 4 gives the detailed meshing information of the using Ti MMC, Al MMC, X38CrMoV 5-3, and Steel materials. Table 4 Mesh Details Structural Analysis Mesh type Solid mesh Mesh Element Type Tetrahedron Jacobian points 4 Element Size m Tolerance m Total Nodes Total Elements Maximum Aspect Ratio This is the information in detail about the meshing of pressure vessel. 201

5 V. Results The simulations and Finite Element Analysis on the pressure vessel which is done considering the Ti MMC, Al MMC, X38CrMoV 5-3, and Steel materials results in Von Mises stress, URES Displacement, ESTRN Strain and Factor of Safety (FOS). In the static studies, fixed supports are used as fixtures at the edges provided of the pressure vessel on which the complete weight of the pressure vessel acts. The results of the analysis in a static study on the pressure vessel with Ti MMC, Al MMC, X38CrMoV 5-3, and Steel materials are shown in Table 5, Table 6, Table 7 and Table 8. The test conditions and the criterion for the analysis are thermal load such as temperature T = 600º C and pressure load P = 60 N/mm 2 are applied in static studies. Von Mises stress failure criterion is used in the static studies. Table 5 Design With Material Von Mises Stress (min) Von Mises Stress (max) Ti - MMC 1.562e e+08 Al - MMC 2.328e e+08 X38CrMoV e e+09 Steel 2.707e e+09 Table 6 Design With Material URES Displacement (min) URES Displacement (max) Ti - MMC 0.000e+00 mm 1.299e+01 mm Al - MMC 0.000e+00 mm 2.070e+01 mm X38CrMoV e+00 mm 7.352e+00 mm Steel 0.000e+00 mm 7.765e+00 mm Table 7 Design With Material ESTRN Strain (min) ESTRN Strain (max) Ti - MMC 1.123e e-03 Al - MMC 2.522e e-03 X38CrMoV e e-03 Steel 9.901e e

6 Table 8 Design With Material Factor of Safety (min) Factor of Safety (max) Ti - MMC 1.054e e+00 Al - MMC 2.177e e+00 X38CrMoV e e+00 Steel 4.222e e+00 The plots are plotted against nodes and Von Mises stress. Plots for Von Mises stress are obtained at different nodes using Probe tool in Static studies. Graph 1, graph 2, graph 3 and graph 4 shows Von Mises stress plots for pressure vessel analysed using Ti MMC, Al MMC, X38CrMoV 5-3, and Steel materials. Graph 1: Von Mises Stress for pressure vessel analyzed with Ti MMC 203

7 Graph 2: Von Mises Stress for pressure vessel analyzed with Al MMC Graph 3: Von Mises Stress for pressure vessel analyzed with X38CrMoV

8 Graph 4: Von Mises Stress for pressure vessel analyzed with Steel The surface plots result for the Von Mises stress are obtained after simulation process at different nodes in Static analysis. The surface plots are plotted against nodes of pressure vessel and Von Mises stress. Figure 3, figure 4, figure 5 and figure 6 shows Von Mises stress plots for pressure vessel analysed using Ti MMC, Al MMC, X38CrMoV 5-3, and Steel materials. 205

9 Figure 3: Von Mises Stress for pressure vessel analyzed with Ti MMC Figure 4: Von Mises Stress for pressure vessel analyzed with Al MMC Figure 5: Von Mises Stress for pressure vessel analyzed with X38CrMoV

10 Figure 6: Von Mises Stress for pressure vessel analyzed with Steel Interpretation of Results The computer simulations in the static studies on the pressure vessel resulted in minimum Von Mises stress and maximum Von Mises stress. The values maximum factor of safety and the minimum factor of safety are greater than 0.5 for all the models analysed using Ti MMC, Al MMC, X38CrMoV 5-3, and Steel materials in static study. Therefore, the models are within the margin of safety. Hence the designs are considered to be successful. VI. Conclusions The values maximum factor of safety and the minimum factor of safety are greater than 0.5 for all the models analysed using Ti MMC, Al MMC, X38CrMoV 5-3, and Steel materials in static study. The minimum and maximum values of Von Mises stress for the study, Ti MMC, Al MMC, X38CrMoV5, and Steel Static studies using the materials Ti MMC, Al MMC, X38CrMoV5, and Steel has the maximum Von Mises Stress value 7.847e+08, 9.507e+08, 1.438e+09, and 1.682e+09 and the minimum Von Mises Stress value is 1.562e+06, 2.328e+06, 1.442e+06, and 2.707e+06 N. The minimum and maximum values of ESTRN Strain for the study Ti MMC, Al MMC, X38CrMoV5, and Steel Static studies using the materials Ti MMC, Al MMC, X38CrMoV5, and Steel has the maximum ESTRN Strain value 5.112e-03, 9.051e-03, 3.268e-03, and 4.207e-03 and the minimum ESTRN stain value is 1.123e-05, 2.522e-05, 5.526e-06, and 9.901e-06. The minimum and maximum values of URES Displacement for the study, Ti MMC, Al MMC, X38CrMoV5, and Steel Static studies using the materials Ti MMC, Al MMC, X38CrMoV5, and Steel has the maximum URES Displacement value 0.000e+00 mm and the minimum URES Displacement value is 1.299e+01 mm, 2.070e+01 mm, 7.352e+00 mm, and 7.765e+00 mm. 207

11 The minimum and maximum values of FOS for the study, Ti MMC, Al MMC, X38CrMoV5, and Steel Static studies using the materials Ti MMC, Al MMC, X38CrMoV5, and Steel has the value minimum FOS 1.054e+00, 2.177e-01, 1.474e+00, and 4.222e-01 and the maximum FOS value is =e+00. Therefore, the study gives the following conclusions that the pressure vessel designed with the X38CrMoV 5 alloy and Ti - MMC can be used in the pressure vessel manufacturing which can sustain under the optimum working conditions of Ultra-supercritical thermal environments. REFERENCES [1] John P Moore, Horizontal Shell Boiler, United States Patent, Patent No.: 4,409,926. [2] Stanley G Finch, Boiler, United States Patent, Patent No.: 4,909,190. [3] John P Moore, Shell Boilers, United States Patent, Patent No.: 4,308,826. [4] Martti Seppanen, Johan Ruotsala, Boiler Plant a Support Structure and a Method for Supporting the Walls of a Steam Boiler of a Boiler Plant, United States Patent, Patent No.: US 2008/ Al. [5] Dewan Shamsuz Zaman, Boiler Structure and Method of Assembly, United States Patent, Patent No.: US 2015/ Al. [6] Kazuya Yamada, Tetsuji Namato, Hidetomo Saimi, Boiler System, United States Patent, Patent No.: US 2015/ Al. [7] R. Viswanathan, W. Bakker, Materials for Ultrasupercritical Coal Power Plants Boiler Materials: Part I, JMEPEG (2001), Volume 10, Page No.: [8] R. Viswanathan, W. Bakker, Materials for Ultrasupercritical Coal Power Plants Boiler Materials: Part II, JMEPEG (2001), Volume 10, Page No.: [9] R. Viswanathan, J.F. Henry, J. Tanzosh, G. Stanko, J. Shingledecker, B. Vitalis, R. Purgert, U.S. Program on Materials Technology for Ultra-Supercritical Coal Power Plants, JMEPEG (2005), Volume 14, Page No.: [10] I.G. Wright, P.J. Maziasz, F.V. Ellis, T.B. Gibbons, D.A. Woodford, MATERIALS ISSUES FOR TURBINES FOR OPERATION IN ULTRA-SUPERCRITICAL STEAM. 208